Yanmar 4TNV98, Service Manual

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4TNV98 & 4TNE98 Diesel Engine 3 Index
Section 1. GENERAL SERVICE
INFORMATION
Component Identification ......................................7
Location of Labels.................................................8
Engine Nameplate (Typical)......................8
Emission Control Regulations ...............................8
EPA / ARB Regulations - USA Only...........8
Emission Control Labels .......................................9
The 97/68/EC Directive Certified Engines..............9
Engine Family.......................................................9
Function of Major Engine Components................ 10
Function of Cooling System Components............ 11
Diesel Fuel.......................................................... 12
Diesel Fuel Specifications....................... 12
Filling The Fuel Tank .............................. 13
Priming the Fuel System......................... 15
Engine Oil........................................................... 16
Engine Oil Specifications ........................ 16
Engine Oil Viscosity................................ 16
Checking Engine Oil............................... 17
Adding Engine Oil................................... 17
Engine Oil Capacity (Typical).................. 17
Engine Coolant ................................................... 18
Engine Coolant Specifications ................ 19
Filling Radiator with Engine Coolant ....... 19
Engine Coolant Capacity (Typical) .......... 20
Specifications...................................................... 20
Description of Model Number ................. 20
Engine General Specifications ................ 21
Principal Engine Specifications............................ 22
4TNV98 EPA Tier 2.............................. 22
4TNE98 EPA Tier 3.............................. 23
Engine Service Standards................................... 24
Tightening Torques for Standard Bolts and Nuts .. 25
Abbreviations and Symbols................................. 27
Abbreviations. ........................................ 27
Symbols ................................................. 27
Unit Conversions ................................................ 28
Unit Prefixes........................................... 28
Units of Length ....................................... 28
Units of Volume ...................................... 28
Units of Mass ......................................... 28
Units of Force......................................... 28
Units of Torque ....................................... 28
Units of Pressure.................................... 28
Units of Power........................................ 28
Units of Temperature .............................. 28
Section 2. PERIODIC MAINTENANCE
Before You Begin Servicing ................................ 29
Introduction ........................................................ 40
The Importance of Periodic Maintenance 40
Performing Periodic Maintenance........... 40
Yanmar Replacement Parts.................... 40
Required EPA / ARB Maintenance-USA Only
.............................................................. 40
EPA / ARB Installation Requirements-USA
Only....................................................... 40
Periodic Maintenance Schedule.......................... 41
Periodic Maintenance Procedures ...................... 43
Drain Fuel Filter / Water Separator ......... 43
4TNE98 For D25S-5 Only ...................... 43
Daily................................................................... 45
After Initial 50 Hours of Operation........... 45
Every 50 Hours of Operation.................. 48
Every 250 Hours of Operation ................ 51
Every 500 Hours of Operation ................ 54
Every 1000 Hours of Operation .............. 59
Every 1500 Hours of Operation .............. 61
Every 2000 Hours of Operation .............. 62
Section 3. ENGINE
Before You Begin Servicing ................................ 63
Introduction ........................................................ 66
Cylinder Head Specifications .............................. 66
Adjustment Specifications ...................... 66
Cylinder Head ........................................ 66
Intake / Exhaust Valve and Guide Cont... 67
Push Rod............................................... 68
Rocker Arm and Shaft ............................ 68
Valve Spring........................................... 68
Camshaft and Timing Gear Train Specifications .. 68
Camshaft ............................................... 68
Idler Gear Shaft and Bushing ................. 69
Timing Gear Backlash ............................ 69
Crankshaft and Piston Specifications .................. 70
Crankshaft ............................................. 70
Thrust Bearing ....................................... 70
Piston .................................................... 71
Connecting Rod ..................................... 72
Tappet.................................................... 72
Cylinder Block Specifications .............................. 73
Cylinder Block........................................ 73
Special Torque Chart .......................................... 73
Torque for Bolts and Nuts ....................... 73
Special Service Tools.......................................... 75