Yanmar 4TNV98 Service Manual Download Page 6

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4TNV98 & 4TNE98 Diesel Engine

Index

Measuring Instruments........................................ 77

Cylinder Head..................................................... 80

Cylinder Head Components.................... 80

Disassembly of 4-Valve Cylinder Head ... 82

4TNE98 Engine...................................... 87

Disassembly of Cylinder Head................ 89

Cleaning of Cylinder Head Components . 92

Inspection of Cylinder Head Components93

Reassembly of Cylinder Head ................ 98

Measuring and Adjusting Valve Clearance......... 104

4TNE98 Engine.................................... 105

4TNV98 Engine.................................... 106

Crankshaft and Camshaft Components ............. 109

Disassembly of Engine ..........................111

Disassembly of Camshaft and Timing
Components..........................................111

Disassembly of Crankshaft and Piston
Components......................................... 116

Inspection of Crankshaft and Camshaft
Components......................................... 120

Honing and Boring................................ 126

Reassembly of Crankshaft and Piston
Components......................................... 127

Reassembly of Camshaft and Timing
Components......................................... 136

Final Reassembly of Engine ................. 138

Section 4. FUEL SYSTEM

Before You Begin Servicing............................... 139

4TNV98 ENGINE.............................................. 141

Introduction .......................................... 141

Fuel Injection Pump.............................. 141

Stop Solenoid....................................... 142

Cold Start Device.................................. 142

Trochoid Fuel Pump ............................. 142

Fuel System Specifications ............................... 143

Special Torque Chart ............................ 143

Test and Adjustment Specifications....... 144

Special Service Tools ........................................ 145

Measuring Instruments...................................... 145

Fuel System Diagram ....................................... 146

Fuel System Components ................................. 147

4-Valve Cylinder Head.......................... 147

Fuel Injection Pump .......................................... 148

Removal of Fuel Injection Pump ........... 148

Installation of Fuel Injection Pump ........ 152

Checking and Adjusting Fuel Injection Timing.... 157

Determining the Fuel Injection Timing

Specification......................................... 157

Checking Fuel Injection Timing............. 158

Adjusting Fuel Injection Timing............. 161

Fuel Injectors.................................................... 163

Removal of Fuel Injectors..................... 163

Testing of Fuel Injectors ....................... 164

Disassembly and Inspection of Fuel
Injectors............................................... 165

Adjusting Fuel Injector Pressure........... 166

Reassembly of Fuel Injectors ............... 167

Installation of the Fuel Injectors ............ 167

4TNE98 ENGINE.............................................. 168

Fuel System Special Torque Chart........ 168

Measuring Instruments......................... 168

Fuel System Components .................... 169

Fuel System Components .................... 170

Structure And Operation Of Fuel Injection
Pump................................................... 171

Overview.............................................. 172

Plunger Operation................................ 175

Process................................................ 176

Reverse Rotation Prevention Mechanism

............................................................ 178

Fuel Injection Volume Adjustment
Mechanism .......................................... 178

Delivery Valve Assembly ...................... 179

Delivery Valve Holder with Damping Valve

............................................................ 179

All - Speed Governor ........................................ 180

At Start of Engine................................. 182

During Idling......................................... 183

At Full-Load Maximum Speed Control .. 184

At No-Load Maximum Speed Control ... 185

Full-Load Position Adjustment Mechanism

............................................................ 186

Structure And Operation Of Timer ..................... 187

Standard Type Automatic Timer............ 187

Magnetic Valve (Stop Solenoid)............ 188

Removal Of Fuel Injection Pump....................... 189

Installation Of The Fuel Injection Pump............. 192

Checking / Adjustment Of Fuel Injection Timing. 194

Servicing The Fuel Injectors.............................. 196

Removal of the Fuel Injectors............... 196

Inspection and Testing of the Fuel Injectors

............................................................ 197

Judgement Criteria on Atomization
Condition ............................................. 199

Installation of Fuel Injectors.................. 200

Summary of Contents for 4TNV98

Page 1: ...rvice Manual 4TNV98 4TNE98 Diesel Engine D20S 5 D25S 5 D30S 5 D33S 5 D35C 5 4TNV98 EM0Q3 EM0Q4 EM0Q5 D20S 5 D25S 5 D30S 5 D33S 5 D35C 5 4TNE98 EM0QC EM0QD EM0QE D20G D25G D30G 4TNE98 SB4319E00 Jan 200...

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Page 3: ...ollowing symbol WARNING Improper operation lubrication maintenance or repair of this product can be dangerous and could result in injury or death Do not operate or perform any lubrication maintenance...

Page 4: ......

Page 5: ...nits 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 Period...

Page 6: ...njection Pump 152 Checking and Adjusting Fuel Injection Timing 157 Determining the Fuel Injection Timing Specification 157 Checking Fuel Injection Timing 158 Adjusting Fuel Injection Timing 161 Fuel I...

Page 7: ...d Oil Pump 215 Oil Pump Components 215 Disassembly of Oil Pump 216 Cleaning and Inspection 216 Reassembly of Oil Pump 217 Section 7 STARTER MOTOR Before You Begin Servicing 219 Introduction 221 Starte...

Page 8: ......

Page 9: ...ction Pump 12 Engine Oil Filter 13 Dipstick Engine Oil 14 Governor Lever 15 Intake Manifold 16 Fuel Filter 17 Fuel Inlet 18 Fuel Return to Fuel Tank 19 Top Filler Port Engine Oil 20 Rocker Arm Cover 2...

Page 10: ...ion of the engine nameplate is shown Figure 4 2 1 4 Engine Nameplate Typical Emission Control Regulations EPA ARB Regulations USA Only Yanmar engines meet Environmental Protection Agency EPA U S Feder...

Page 11: ...ight find on your engine EPA ARB Labels EPA Greater than or Equal to 50 HP SAE 37kW EPA and ARB The 97 68 EC Directive Certified Engines The engines described in this manual have been certified by the...

Page 12: ...lter removes contaminants and sediments from the diesel fuel Periodic replacement of the fuel filter is necessary See the Periodic Maintenance Schedule on page 39 for the replacement frequency Please...

Page 13: ...the engine cooling fan circulates air through the radiator the heat is transferred to the air Radiator Cap The radiator cap controls the cooling system pressure The cooling system is pressurized to ra...

Page 14: ...t not exceed 0 35 by volume Less than 0 1 is preferred The total aromatics content should not exceed 35 by volume Less than 30 is preferred The PAH polycyclic aromatic hydrocarbons content should be b...

Page 15: ...the precautions and concerns above may affect the warranty coverage of your engine Filling The Fuel Tank DANGER FIRE AND EXPLOSION HAZARD Diesel fuel is flammable and explosive under certain condition...

Page 16: ...iesel fuels recommended by Yanmar for the best engine performance to prevent engine damage and to comply with EPA ARB warranty requirements Only use clean diesel fuel NEVER remove the primary strainer...

Page 17: ...out of the air bleed port is free of bubbles 4 Tighten the air bleed port 5 Wipe up any spills and properly dispose of fuel 6 NEVER use the starter motor to crank the engine in order to prime the fuel...

Page 18: ...E 5 JASO Service Category DH 1 Definitions API Classification American Petroleum Institute ACEA Classification Association des Constructeurs Europ ens d Automobilies JASO Japanese Automobile Standard...

Page 19: ...at the top or the side engine oil filler port Figure 4 5 5 4 Wait three minutes and check the oil level 5 Add more oil if necessary 6 Reinstall the oil cap Figure 4 5 4 and hand tighten Over tightenin...

Page 20: ...rain the engine coolant Hot engine coolant may splash and burn you Failure to comply could result in death or serious injury CAUTION COOLANT HAZARD Wear eye protection and rubber gloves when you handl...

Page 21: ...ntainer Water quality is important to coolant performance Yanmar recommends that soft distilled or demineralized water be used to mix with coolants NEVER mix extended or long life coolants and convent...

Page 22: ...nt will leak out instead of going into the reserve tank 7 Run the engine until it is at operating temperature Check the level of engine coolant in the reserve tank When the engine is running and the e...

Page 23: ...information described in Principal Engine Specifications is for a standard engine To obtain the information for the engine installed in your driven machine please refer to the manual provided by the d...

Page 24: ...m Forced Lubrication with Trochoid Pump Normal Oil Pressure at Rated Engine Speed 42 57 psi 0 29 0 39 MPa 2 96 3 98 kgf cm Normal Oil Pressure at Low Idle Speed 8 5 psi 0 06 MPa 0 6 kgf cm or greater...

Page 25: ...diator Lubricating System Forced Lubrication With Trochoid Pump At normal operating speeds oil pressure is 42 57 psi 0 29 0 39 MPa 3 0 4 0 kgf cm At idle oil pressure is No less than 18 5 psi 0 13 Mpa...

Page 26: ...36 kgf cm 384 414 psi 2 65 2 85 MPa 27 29 kgf cm See Troubleshooting By Measuring Compression Pressure on page 236 Compression Pressure at 250 rpm 250 min 4TNE98 425 428 psi 2 93 2 95 MPa 29 31 kgf cm...

Page 27: ...pplying excessive torque may damage the fastener or component and not enough torque may cause a leak or component failure CAUTION The tightening torque in the Standard Torque Chart see General Service...

Page 28: ...the value at left when the tightening part is aluminum Use 60 of the value at left for 4T bolts and lock nuts 1 8 mm 7 ft lb 87 in lb 9 8 N m 1 0 kgf m 1 4 mm 14 ft lb 173 in lb 19 6 N m 2 0 kgf m 3...

Page 29: ...r minute g gram gal gallon U S gal hr gallon U S per hour gal min gallon U S per minute GL gear lubricant hp horsepower U S hr hour I D inside diameter ID identification IDI indirect injection in inch...

Page 30: ...0 2248 lbf N x 0 1020 kgf kgf x 2 2050 lbf kgf x 9 8070 N Units of Torque ft lb x 1 3558 N m ft lb x 0 1383 kgf m in lb x 0 1130 N m in lb x 0 0115 kgf m kgf m x 7 2330 ft lb kgf m x 86 8000 in lb kg...

Page 31: ...ne coolant will spurt out and seriously burn you Allow the engine to cool down before you attempt to remove the radiator cap Tighten the radiator cap securely after you check the radiator Steam can sp...

Page 32: ...th the engine running Failure to comply will result in death or serious injury DANGER FIRE AND EXPLOSION HAZARD Diesel fuel is flammable and explosive under certain conditions Be sure to place the die...

Page 33: ...under pressure and fuel could spray out when you remove any fuel system component Failure to comply will result in death or serious injury DANGER FIRE AND EXPLOSION HAZARD Diesel fuel is flammable and...

Page 34: ...result in death or serious injury WARNING SEVER HAZARD Keep hands and other body parts away from moving rotating parts such as the cooling fan flywheel or PTO shaft Wear tight fitting clothing and kee...

Page 35: ...rom hot engine surfaces such as the muffler exhaust pipe turbocharger if equipped and engine block during operation and shortly after you shut the engine down These surfaces are extremely hot while th...

Page 36: ...id NEVER allow battery fluid to come in contact with clothing skin or eyes Severe burns could result ALWAYS wear safety goggles and protective clothing when servicing the battery If battery fluid cont...

Page 37: ...eone may accidentally start the engine and not realize you are servicing it This could result in a serious injury If you must service the engine while it is operating remove all jewelry tie back long...

Page 38: ...overage cause internal engine components to seize and or shorten engine life Prevent dirt and debris from contaminating the engine oil Carefully clean the oil cap dipstick and the surrounding area bef...

Page 39: ...start and the engine oil may not flow easily Contact your authorized Yanmar industrial engine dealer or distributor if the engine will be operated outside of this standard temperature range CAUTION N...

Page 40: ...ng This may damage the starter motor pinion and or ring gear CAUTION It is important to perform daily checks Periodic maintenance prevents unexpected downtime reduces the number of accidents due to po...

Page 41: ...rranty coverage on your engine See Yanmar Limited Warranty in Warranty Section Consult your authorized Yanmar dealer or distributor for assistance when checking items marked with a CAUTION If the fuel...

Page 42: ...to comply could result in death or serious injury Perform periodic maintenance procedures in an open level area free from traffic If possible perform the procedures indoors to prevent environmental c...

Page 43: ...to establish definitively The following should be treated only as a general guideline CAUTION Establish a periodic maintenance plan according to the engine application and make sure you perform the r...

Page 44: ...nt Check Battery Check Engine Oil Level Check Engine Oil Pressure Indicator Drain and Fill Engine Oil Engine Oil Replace Engine Oil Filter 1st time 2nd and after Engine Speed Control Check and Adjust...

Page 45: ...serious injury 0000009en 4TNE98 For D25S 5 Only WARNING HIGH PRESSURE HAZARD Avoid skin contact with high pressure diesel fuel spray caused by a fuel system leak such as a broken fuel injection line...

Page 46: ...e scheduled periodic maintenance if the fuel filter indicator comes on The fuel filter water separator contains a sensor to detect the amount of water and contaminants This sensor sends a signal to an...

Page 47: ...oil specified Other engine oils may affect warranty coverage cause internal engine components to seize and or shorten engine life Prevent dirt and debris from contaminating the engine oil Carefully cl...

Page 48: ...o collect waste oil Figure 5 1 6 Remove the oil drain plug Figure 5 2 1 from the engine oil pan Allow oil to drain 7 After all oil has been drained from the engine reinstall the oil drain plug Figure...

Page 49: ...y engine oil is spilled wipe it away with a clean cloth Check and Adjust Cooling Fan V Belt The V belt will slip if it does not have the proper tension This will prevent the alternator from generating...

Page 50: ...ing run the engine for 5 minutes or more Check the tension again using the specifications for a used V belt Used V Belt Tension A B C 3 8 1 2 in 10 14 mm 1 4 3 8 in 7 10 mm 5 16 1 2 in 9 13 mm Every 5...

Page 51: ...are discovered The cup of the separator is made from semi transparent material In the cup is a red colored float ring The float ring will rise to the surface of the water to show how much needs to be...

Page 52: ...CAUTION ALWAYS be environmentally responsible Follow the guidelines of the EPA or other governmental agencies for the proper disposal of hazardous materials such as engine oil diesel fuel and engine c...

Page 53: ...ve Wipe up any spills immediately Wear eye protection The fuel system is under pressure and fuel could spray out when you remove any fuel system component Failure to comply will result in death or ser...

Page 54: ...fins apply detergent thoroughly clean and rinse with tap water CAUTION NEVER use high pressure water or compressed air at greater than 28 psi 193 kPa 19 686 mmAq or a wire brush to clean the radiator...

Page 55: ...low or high idle speed limit screw This may impair the safety and performance of the machine and shorten its life If the idle speed limit screws require adjustment see your authorized Yanmar industria...

Page 56: ...R operate the engine with the air cleaner element s removed This may allow foreign material to enter the engine and damage it Every 500 Hours of Operation Perform the following maintenance every 500 h...

Page 57: ...rag are flammable and explosive Wipe up any spills immediately Wear eye protection The fuel system is under pressure and fuel could spray out when you remove any fuel system component Failure to comp...

Page 58: ...r leaks 4TNE98 for D25S 5 Only Replace the fuel filter at specified intervals to prevent contaminants from adversely affecting the diesel fuel flow 1 Stop the engine and allow it to cool 2 Close all f...

Page 59: ...tall the new fuel filter Figure 5 14 2 by turning it to the right Figure 5 14 4 until it contacts the mounting surface Tighten one additional turn 18 Open all fuel cocks in the fuel line 19 Reconnect...

Page 60: ...ter Separator on page 41 4 Turn the retaining ring Figure 5 15 5 to the left Figure 5 15 10 and remove the cup Figure 5 15 6 If equipped disconnect the sensor wire Figure 5 15 7 from the cup before re...

Page 61: ...n and rubber gloves when you handle long life or extended life engine coolant If contact with the eyes or skin should occur flush eyes and wash immediately with clean water Failure to comply may resul...

Page 62: ...ll and tighten the drain plug or close the drain cock in the radiator Reinstall and tighten the cylinder block drain plug or reconnect the coolant hose at the oil cooler 6 Fill radiator and engine wit...

Page 63: ...is procedure is considered normal maintenance and is performed at the owner s expense This procedure is not covered by the Yanmar Limited Warranty Inspect Crankcase Breather System Proper operation of...

Page 64: ...Fuel Hoses and Engine Coolant Hoses CAUTION ALWAYS be environmentally responsible Follow the guidelines of the EPA or other governmental agencies for the proper disposal of hazardous materials such as...

Page 65: ...s and clothing away from moving rotating parts Failure to comply could result in death or serious injury WARNING FUME BURN HAZARD Always read and follow safety related precautions found on containers...

Page 66: ...versely affect the properties of the engine coolant CAUTION Identify all parts and their location using an appropriate method It is important that all parts are returned to the same position during th...

Page 67: ...ting rod assemblies together to be returned to the same position during the reassembly process Label the parts using an appropriate method CAUTION Do not allow the honing tool to operate in one positi...

Page 68: ...ion 4TNV98 4 Valve Head Intake Exhaust 0 0142 0 0220 in 0 36 0 56 mm 0 0138 0 0217 in 0 35 0 55 mm 0 0315 in 0 8 mm 0 0315 in 0 8 mm See Valve Recession on Page 95 and 98 Intake 120 Seat Angle Exhaust...

Page 69: ...d 103 Valve Guide Installation Method Cold fitted Valve Stem Seal Projection From Cylinder Head 0 460 0 472 in 11 7 12 0 mm See Reassembly of Intake and Exhaust Valves on page 98 4TNE98 Engine Inspect...

Page 70: ...spection Item Model Standard Limit Reference Page 4TNV98 4 Valve Head 1 5630 in 39 7 mm 1 5433 in 39 2 mm Free Length 4TNE98 1 87 in 47 5 mm 4TNV98 4 Valve Head 0 0551 in 1 4 mm Squareness 4TNE98 0 05...

Page 71: ...mm Camshaft Outside Diameter 1 9655 1 9665 in 49 925 49 950 mm 1 9642 in 49 890 mm Flywheel End Oil Clearance 0 0020 0 0039 in 0 050 0 100 mm 0 0083 in 0 210 mm See Inspection of Camshaft on page 125...

Page 72: ...onnecting Rod Journals Oil Clearance 0 0015 0 0029 in 0 038 0 074 mm 0 0059 in 0 150 mm See Inspection of Crankshaft on Page 124 Journal Outside Diameter 2 5572 2 5576 in 64 952 64 962 mm 2 5552 in 64...

Page 73: ...pection Item Standard Limit Reference Page Ring Groove Width 0 0803 0 0811 in 2 040 2 060 mm Ring Width 0 0764 0 0772 in 1 940 1 960 mm 0 0756 in 1 920 mm Side Clearance 0 0031 0 0047 in 0 080 0 120 m...

Page 74: ...page 124 Connecting Rod Big End Inspection Item Standard Limit Reference Page 4TNV98 0 0079 0 0157 in 0 20 0 40 mm Side Clearance Thrust Clearance 4TNE98 0 0051 0 0091 in See Inspection of Connecting...

Page 75: ...or less 0 0012 in 0 03 mm See Inspection of Cylinder Block on page 121 Special Torque Chart Torque for Bolts and Nuts Component Thread Diameter and Pitch Torque Lubricating Oil Application Thread Por...

Page 76: ...9 127 5 N m 11 0 13 0 kgf m Applied Fuel Injector Bolt 4TNV98 M8 x 1 25 mm 17 21 ft lb 22 6 28 4 N m 2 3 2 9 kgf m Not Applied Fuel Pump Drive Gear Nut 4TNV98 M18 x 1 5 mm 83 90 ft lb 113 123 N m 11 5...

Page 77: ...551 in 14 mm 0 787 in 20 mm 2 Valve Guide Tool For Installing Valve Guide Locally Manufactured L1 L2 d1 d2 0 787 in 20 mm 3 937 in 100 mm 1 181 in 30 mm 1 299 in 33 mm 4 Connecting Rod Bushing Replace...

Page 78: ...amshaft Bushing Tool For Extracting Camshaft Bushing Locally Manufactured Yanmar Part No Cylinder Bore 9 Flex Hone For Preparation of Cylinder Walls 129400 92440 3 504 3 976 in 89 101 mm 10 Piston Rin...

Page 79: ...Available For holding the dial gauge when measuring 4 Micrometer Locally Available For measuring the outside diameters of crankshaft pistons piston pins etc 5 Cylinder Bore Gauge Locally Available Fo...

Page 80: ...nd valve adjustment clearance 12 Battery Coolant Tester For checking concentration of antifreeze and the battery electrolyte charge status 13 Digital Thermometer For measuring temperatures Contact Typ...

Page 81: ...on 15 Circuit Tester For measuring resistance voltage and continuity of electrical circuits Compression Gauge Kit For measuring compression pressureGauge Set Part No TOL 97190080 16 New Comperssion Te...

Page 82: ...4TNV98 4TNE98 Diesel Engine Section 3 Engine 80 Cylinder Head Cylinder Head Components 4TNV98 Engine Figure 6 36...

Page 83: ...14 Valve Adjusting Screw Lock Nut Primary 15 Rocker Arm Shaft Aligning Stud 16 Fuel Injector Retainer 17 Valve Stem Seal 18 Valve Guide 19 Cylinder Head 20 Intake Valve 21 Exhaust Valve 22 Cylinder He...

Page 84: ...e7 31 Figure 6 37 CAUTION Remove or install the high pressure fuel injection lines as an assembly whenever possible Disassembling the high pressure fuel injection lines from the retainers or bending a...

Page 85: ...e a flat blade screwdriver Figure 6 39 to remove the fuel injection line grommets Figure 6 40 1 from the valve cover Figure 6 40 3 and fuel injectors Figure 6 40 2 There is a notch at the 3 o clock po...

Page 86: ...Identify all parts so that they will be reinstalled in their original locations Figure 6 41 Disassembly of Rocker Arm Assembly NOTE Identify the rocker arms so they can be reinstalled with the origin...

Page 87: ...ts Figure 6 44 1 3 Lift the cylinder head away from the cylinder block Discard the cylinder head gasket Figure 6 44 2 Place the cylinder head on the work bench to prevent damage to the combustion surf...

Page 88: ...nal location 7 Remove the injector nozzle protectors Figure 6 46 6 and the seats Figure 6 46 7 8 Turn the cylinder head so the exhaust port side faces down Remove the intake and exhaust valves Figure...

Page 89: ...4TNV98 4TNE98 Diesel Engine Section 3 Engine 87 4TNE98 Engine Figure 6 1...

Page 90: ...p 10 Valve Keepers 11 Spring Retainer 12 Valve Spring 13 Valve Stem Seal 14 Valve Guide 15 Intake Valve 16 Exhaust Valve 17 Cylinder Head Gasket 18 Cylinder Head 19 Glow Plug 20 Glow Plug Cover 21 Pus...

Page 91: ...ve the exhaust manifold bolts Figure 6 2 4 and nuts Figure 6 2 5 Remove the exhaust manifold Figure 6 2 6 Discard the exhaust manifold gasket Figure 6 2 7 3 Remove the water pump from the engine See D...

Page 92: ...Arm Assembly 1 Remove the rocker arm shaft alignment screw Figure 6 7 1 from the support bracket that secures the rocker arm shaft Figure 6 7 2 2 Remove the retaining rings Figure 6 7 3 from the ends...

Page 93: ...r head bolts Figure 6 9 1 3 Lift the cylinder head away from the cylinder block Discard the cylinder head gasket Figure 6 9 2 Position the cylinder head on the work bench to prevent damage to the comb...

Page 94: ...em so they can be installed in their original location 7 Turn the cylinder head so the exhaust port side faces down Remove the intake and exhaust valves Figure 6 11 6 from the cylinder head Removal of...

Page 95: ...ice as determined from the state of current rate of wear should be replaced even though the part currently meets the service standard limit Inspection of Push Rods Push Rod Bend 1 Place the push rods...

Page 96: ...e valve guides while they are installed in cylinder head Use a telescoping gauge and micrometer to measure the inside diameter at each end of the valve guide Measure in three places and 90 apart Figur...

Page 97: ...e limit Figure 6 53 Valve Stem Bend Place the valve stem on a flat inspection block or layout bed Roll the valve until a gap can be observed between a portion of the valve stem and the surface of the...

Page 98: ...valves and valve seats can be lapped or ground to return them to serviceable condition Severely worn or damaged components will require replacement Coat the valve seat with a thin coat of bluing compo...

Page 99: ...es Check for fractures on the inside and outside portions of the springs If the valve spring is fractured replace the valve spring Corrosion Check for corrosion of spring material caused by oxidation...

Page 100: ...after removing the valve guides from the freezer insert the valve guides Figure 6 62 1 in their proper positions 4TNV98 Engine 4TNE98 Engine Figure 6 62 3 Finish installing the valve guides Figure 6 6...

Page 101: ...its exhaust port side 4 Place all the valves Figure 6 66 5 in their proper location in the cylinder head 4TNV98 Engine 4TNE98 Engine Figure 6 66 5 Place the cylinder head on the workbench with the com...

Page 102: ...7 2 on the cylinder block 2 Position the cylinder head on the on the cylinder head gasket 4TNV98 Engine 4TNE98 Engine Figure 6 67 3 Lightly oil the threads of the cylinder head bolts Figure 6 67 1 Tig...

Page 103: ...r original locations Figure 6 69 IMPORTANT The wave washers Figure 6 70 2 must be installed with the bow facing the rocker arms Figure 6 70 1 Figure 6 70 IMPORTANT Ensure the lubrication holes Figure...

Page 104: ...t Slide the rocker arm support brackets Figure 6 30 4 springs Figure 6 30 5 and rocker arms Figure 6 30 6 onto the shaft NOTE The rocker arm shaft fits tightly in the rocker arm support brackets Clamp...

Page 105: ...en the bolts to specification 7 Reconnect the fuel injector return hose and fuel injection pump coolant hoses 8 Reinstall the high pressure fuel line grommets into the valve cover 9 Reinstall the high...

Page 106: ...ble in the timing port of the flywheel housing If there is no valve clearance and the cylinder is at TDC of the compression stroke extreme wear or damage to the cylinder head or valves may be possible...

Page 107: ...on page 103 NOTE If adjusting each cylinder individually the cylinder to be adjusted first does not have to be the No 1 cylinder Select and adjust the cylinder where the piston is nearest to the top...

Page 108: ...ng grid on the flywheel Position where both the intake and exhaust valves are closed 3 Make sure there is clearance Figure 6 77 5 between the valve bridge Figure 6 77 1 and the rocker arm Figure 6 77...

Page 109: ...ations on page6 6 between the rocker arm Figure 6 82 2 and valve bridge Figure 6 82 3 Record the results and use this value as an indication of wear Figure 6 82 9 If adjustment is required proceed to...

Page 110: ...ure 6 83 4 while tightening the valve adjusting screw lock nut Figure 6 83 5 Recheck the clearance 13 Apply oil to the contact surface between the adjusting screw and push rod 14 Rotate the crankshaft...

Page 111: ...4TNV98 4TNE98 Diesel Engine Section 3 Engine 109 Crankshaft and Camshaft Components Figure 6 84...

Page 112: ...er Gear 18 Oil Pickup O Ring 19 Oil Pickup 20 Crankshaft 21 Parallel Pin 22 Crankshaft Gear Key 23 Crankshaft Gear 24 Crankshaft Pulley 25 Main Bearing Inserts 26 Main Bearing Cap 27 Oil Pan 28 Thrust...

Page 113: ...ine falling during work on the engine 6 Clean the engine by washing with solvent air or steam cleaning Carefully operate so as to prevent any foreign matter or fluids from entering the engine or any f...

Page 114: ...ot allow the gear being checked to move axially as excess end play could cause a false reading Figure 6 86 1 Fuel Injection Pump Drive Gear 2 Camshaft Drive Gear 3 Auxiliary Drive Gear Optional 4 Cran...

Page 115: ...ing a gear puller 3 Removal of the camshaft gear requires the camshaft be removed and placed in a press Do not remove the camshaft gear unless it or the camshaft is damaged and requires replacement Se...

Page 116: ...Method A Install a dial indicator Figure 6 92 1 on the cylinder block Move the camshaft Figure 6 92 2 back and forth to measure the end play Record the measurement See Camshaft on page 68 for the ser...

Page 117: ...cation 6 Remove the camshaft drive gear Figure 6 94 4 only if the gear or camshaft require replacement Use a knife edge puller and a press to remove the gear The gear is a shrink fit and will need to...

Page 118: ...possible to remove the pistons Use a suitable ridge reamer to remove ridges and carbon prior to removing the pistons NOTE Pistons can fall from cylinder block if the engine is inverted Rotate the engi...

Page 119: ...Compare the width of the flattened PLASTIGAGE to the graduation marks on the package Figure 6 99 1 The mark that most closely matches the width of the flattened PLASTIGAGE will indicate the bearing o...

Page 120: ...ed Removal of Crankshaft 1 Remove the flywheel Figure 6 101 1 from the crankshaft 2 Remove the bolts from the rear oil seal assembly Figure 6 101 2 3 Remove the assembly from the engine Figure 6 101 3...

Page 121: ...the markings on the main bearing caps or mark them yourself so they can be reinstalled in the same order as they were removed Do not remove the bearing inserts at this time NOTE The arrows on the main...

Page 122: ...the crankshaft gear unless the gear or crankshaft are damaged and require replacement 8 If necessary remove the crankshaft gear Figure 6 107 1 parallel pin Figure 6 107 2 and key Figure 6 107 3 If usi...

Page 123: ...ce Oil clearance should be checked during disassembly to determine the extent of wear and during assembly to ensure long engine life The same procedure is done for both connecting rods and main bearin...

Page 124: ...grooves 4 Measure the diameter of the piston skirt at 90 to the wrist pin bore as shown Figure 6 111 Measurements must be taken at a specified distance Figure 6 111 1 from the bottom of the piston ba...

Page 125: ...fications Replace the piston if not within specification Figure 6 114 10 To measure piston ring end gap insert each compression piston ring Figure 6 115 1 one at a time into the cylinder Use a piston...

Page 126: ...iameter See Crankshaft on page 70 for specifications Inspection of Tappets 1 Inspect the tappet contact surfaces for abnormal wear Figure 6 117 1 Normal wear will be even as shown in Figure 6 117 2 Sl...

Page 127: ...ation grind the journals and install undersize bearings or replace the crankshaft Figure 6 120 Inspection of Camshaft 1 Use V blocks and a dial indicator to check camshaft bend Figure 6 121 Place the...

Page 128: ...condition Slight imperfections can be corrected by honing alone 1 Boring Significant cylinder damage may be corrected by boring the cylinder to an oversize dimension Refer to the appropriate parts ca...

Page 129: ...with hot water and dry with compressed air Apply clean engine oil to all steel surfaces to prevent rusting Reassembly of Crankshaft and Piston Components NOTES Proceed slowly Make no forced assemblies...

Page 130: ...ton and connecting rod are different depending on engine model Piston to Connecting Rod Orientation By Model Orient the piston identification mark stamped on top of the piston on the same side as the...

Page 131: ...on Connecting Rod 4 Rod and Cap Match Marks 5 Flywheel End of Engine 6 Camshaft Side of Engine 1 Lubricate and reinstall the wrist pin Figure 6 131 3 through the piston and connecting rod 2 Reinstall...

Page 132: ...ession ring Figure 6 133 1 This ring is identified by its silver color and barrel shaped face profile IMPORTANT The oil ring expander Figure 6 133 4 end gap must be located 180 from the oil ring Figur...

Page 133: ...gure6 70 3 through the piston and wrist pin bushing 6 Install the second circlip Figure6 70 4 7 Install the piston rings Use piston ring pliers to install the piston rings Install each piston ring on...

Page 134: ...ure 6 135 1 and thrust bearing Figure 6 135 2 in the cylinder block and main bearing caps Apply a liberal coat of clean engine oil to the bearings and crankshaft journals 3 Place the crankshaft into t...

Page 135: ...age 73 for specifications Figure 6 136 Installation of Pistons IMPORTANT Do not allow the connecting rod to contact the crankshaft journal during piston installation Damage to the crankshaft bearing j...

Page 136: ...e engine and the embossed mark on the connecting rod Figure 6 138 3 must face the flywheel end Figure 6 138 5 of the engine Figure 6 138 1 Fuel Injection Pump Side of Engine 2 Piston Identification Ma...

Page 137: ...nstall the piston into No 1 cylinder Be sure the punched mark on the connecting rod is facing the fuel injector side and the embossed mark on the connecting rod is facing the flywheel Figure 6 78 4 In...

Page 138: ...er block so that gravity will keep the tappets Figure 6 143 5 in place and out of the way of the camshaft lobes when the camshaft is being reinstalled NOTE If the engine is not installed on an engine...

Page 139: ...ard the top of the engine 6 Ensure all three timing marks Figure 6 144 A B C are aligned 7 When all gears are properly aligned tighten the idler gear retaining bolts to specified torque See Special To...

Page 140: ...t hole 3 Reinstall the oil pan and tighten the bolts securely Figure 6 149 Final Reassembly of Engine 1 Reinstall the starter motor 2 Reinstall the cylinder head See Reassembly of Cylinder Head on pag...

Page 141: ...could result in death or serious injury WARNING Never inject fuel toward you Since the fuel is injected at high pressure from the nozzle it may penetrate the skin resulting in injury Never inject fuel...

Page 142: ...efore engaging the transmission or any PTOs Engaging the transmission or PTO at an elevated engine speed could result in an unexpected movement of the equipment CAUTION Remove or install the high pres...

Page 143: ...th or removing these devices may void the Yanmar Limited Warranty Figure 7 1 The following describes the features of the MP fuel injection pump manufactured by Yanmar The fuel injection pump is a very...

Page 144: ...ngine not continuing to run with the key switch returned to the ON or RUN position or the engine failing to stop when the key switch is turned to the OFF position Use a multimeter or continuity light...

Page 145: ...r Nut 4TNV98 83 91 ft lb 113 123 N m 11 5 12 5 kgf m Not Applied High Pressure Fuel Injection Line Nuts 22 25 ft lb 29 34 N m 3 0 3 5 kgf m Not Applied Fuel Return Line Bolts 69 87 in lb 7 8 9 8 N m 0...

Page 146: ...5 MPa 5 0 kgf cm after about 5 hours of operation due to the initial break in of the engine When adjusting a new fuel injector or after it has been disassembled for service adjust the fuel injector 72...

Page 147: ...pray pattern of fuel injection nozzle and measuring injection pressure Dial Indicator Mituotoyo 2050SB Locally Available Check and adjust fuel injection timing 2 Extension Rod Mituotoyo 303613 Locally...

Page 148: ...ter 5 Air Bleed Orifice 6 Fuel Supply Line 7 Low Pressure Gallery 8 Pressure Control Valve 9 Trochoid Pump 10 Oil Seal 11 Fuel Injection Pump Cam 12 Engine Crankcase 13 Tappet 14 High Pressure Gallery...

Page 149: ...njection Pump Drive Gear Nut 9 Lock Washer 10 Fuel Injection Pump Drive Gear Assembly DO NOT remove or loosen the four bolts that fasten the injection pump drive gear to the injection pump drive gear...

Page 150: ...l injection pump CAUTION Remove or install the high pressure fuel injection lines as an assembly whenever possible Disassembling the high pressure fuel injection lines from the retainers or bending an...

Page 151: ...re 7 9 2 from the pump IMPORTANT Take care to not damage or bend the oil line In some applications it may be preferable to remove the complete oil line assembly from the engine before proceeding NOTE...

Page 152: ...on pump to become misaligned On 4TNV98 model engines the idler gear is visible Make a reference mark Figure 7 12 1 across both the fuel injection pump drive gear and the idler gear Figure7 12 CAUTION...

Page 153: ...arefully remove the drive gear nut Figure 7 15 1 and lock washer Figure 7 15 2 Figure 7 15 22 Locate the mark stamped into the upper outside mounting boss of the fuel injection pump Highlight this mar...

Page 154: ...the fuel injection pump and governor assembly These adjustments have been made at the factory to meet all applicable emissions regulations and then sealed NEVER attempt to make any adjustments to thes...

Page 155: ...reference marks made earlier 4TNV98 model engines Figure 7 21 1 Figure 7 21 2 If installing the fuel injection pump on an engine with the front gear case cover removed the fuel injection pump drive ge...

Page 156: ...nd tighten the drive gear nut to the specified torque See Special Torque Chart on page 143 Figure 7 23 If reinstalling the original fuel injection pump Align the reference marks Figure 7 24 1 previous...

Page 157: ...e 7 27 1 by the calculated positive amount adjust the fuel injection pump to the calculated value If the difference between the timing index numbers is a negative number the replacement injection pump...

Page 158: ...the pump cover and tighten the cover bolts 10 Reconnect the fuel return lines fuel supply line and coolant lines to the fuel injection pump 11 Reinstall the fuel injection high pressure lines Tighten...

Page 159: ...ll the cooling fan guard if equipped 16 Prime the fuel system See Priming the Fuel System on page 15 17 Operate the engine and check for fuel and coolant leaks Checking and Adjusting Fuel Injection Ti...

Page 160: ...17 6 Fuel injection Timing Record the calculated fuel injection timing specification Checking Fuel Injection Timing NOTE Some fuel may drain from the fuel injection pump during this process Make prov...

Page 161: ...ate the crankshaft in a clockwise direction while looking through the flywheel inspection port Figure7 39 1 Rotate the crankshaft until the injection timing marks on the flywheel are visible Figure 7...

Page 162: ...onger marks is approximately 2 0 cm and the distance from the TDC mark is approximately 4 0cm the answer is approximately 2 This indicates there is 10 2x5 between the TDC mark and the first longer mar...

Page 163: ...Adjusting Fuel Injection Timing on page 161 13 If the injection timing is correct remove the dial indicator and adapter Replace the pump plunger plug and its copper gasket and tighten to specification...

Page 164: ...uel injection pump until the dial indicator reads 2 5 mm 0 098 in 6 To advance the injection timing rotate the top of the fuel injection pump away from the engine 7 To retard the injection timing rota...

Page 165: ...4 Remove the fuel injector mounting clamp bolts Figure7 48 2 Lift the injector mounting clamps Figure7 48 3 away from injector 5 Remove the fuel injector Figure7 48 4 from the cylinder head Figure 7 4...

Page 166: ...highly flammable and may cause a fire or burn skin CAUTION FLYING OBJECT HAZARD ALWAYS wear eye protection when servicing the engine and when using compressed air or high pressure water Dust flying d...

Page 167: ...e Adjusting Fuel Injector Pressure on page 166 Disassembly and Inspection of Fuel Injectors CAUTION Never use a steel wire brush to clean fuel injectors Damage to the nozzle and other components is li...

Page 168: ...cal pull the nozzle valve about 2 3 of the way out Figure 7 54 c Release the valve It should fall smoothly to its seat by it s own weight Figure 7 54 8 Replace the fuel injector assembly if it fails a...

Page 169: ...vise with the nozzle end up 2 Reinstall the shims nozzle spring nozzle spring seat valve stop spacer nozzle valve and nozzle body 3 Reinstall the nozzle case nut Tighten it to specification See Specia...

Page 170: ...Fuel Injector 29 4 ft lbs 39 2 N m 4 kgf m Not Applied See Installation of Fuel Injectorson page 200 Fuel Pump Drive Gear Nut 43 5 51 0 ft lbs 59 69 N m 6 0 7 0 kgf m Not Applied See Installation of...

Page 171: ...4TNV98 4TNE98 Diesel Engine Section 4 Fuel System 169 Fuel System Components Figure 7 1...

Page 172: ...y the feed pump in order to feed fuel into the injection pump chamber Although the fuel pressure in the pump chamber is proportional to the pump revolution excessive fuel is returned to the suction sy...

Page 173: ...4TNV98 4TNE98 Diesel Engine Section 4 Fuel System 171 Structure And Operation Of Fuel Injection Pump Figure 7 3...

Page 174: ...older Governor Figure 7 5 The governor is located above the inspection pump chamber and mainly consists of a flyweight holder and governor lever assembly The flyweight holder holds four flyweights and...

Page 175: ...e advance direction counter revolution direction to early the injection timing Thus the timer controls the fuel injection timing according to the fuel pressure in the pump chamber Feed Pump Vane Type...

Page 176: ...the fuel feeding pressure of the feed pump the fuel compresses the regulating valve spring to lift the piston The fuel is then returned to the suction side as shown by the arrow in the figure It is th...

Page 177: ...ctivate the plunger s reciprocating operation When the inlet port of the plunger barrel being pressed into the distributor head and the inlet slit of the plunger overlap the plunger draws fuel and app...

Page 178: ...jection Process Figure 7 12 Figure 7 13 The plunger begins rotating at the same time the lifting process of the cam disc begins When the inlet port of the plunger barrel is covered by the plunger pres...

Page 179: ...ing so the delivery valve closes to terminate pressure feeding of fuel Uniform Pressure Process Figure 7 16 Figure 7 17 When the plunger turns a further 180 after the end of fuel injection the uniform...

Page 180: ...ssurized resulting in non injection state Fuel Injection Volume Adjustment Mechanism Figure 7 19 The fuel injection volume is increased or decreased by changing the control sleeve position resulting i...

Page 181: ...el in the pipe by the amount equal to the suck back stroke of the piston Delivery Valve Holder with Damping Valve Figure 7 21 The delivery valve holder with damping valve functions to prevent cavitati...

Page 182: ...s the governor sleeve and presses the governor lever assembly to the right The governor lever assembly mainly consists of the corrector leer tension lever and start lever Corrector lever fulcrum M is...

Page 183: ...ng which is connected to the control lever Movement of the control lever is capable of changing the set force of the governor spring On the upper back of the tension lever is the idle spring The gover...

Page 184: ...sion lever is pulled until it comes into contact with press in pin M3 by governor spring force At the same time the start lever is released from the tension lever by the start spring force to press th...

Page 185: ...f the governor spring becomes zero Therefore the flyweight opens outwardly even at low revolutions to move the governor sleeve to the right This makes the start lever turn clockwise with M2 being the...

Page 186: ...t the tension of the governor spring becomes maximum At this time the tension lever is fixed at the position where is contacts pin M3 being pressed into the pump housing The idle spring is completely...

Page 187: ...to make the governor lever assembly turn clockwise with fulcrum M2 As a result the control sleeve moves in the direction of no injection to the left for controlling speed so as not to exceed the full...

Page 188: ...oad position is determined by the amount the full load adjusting screw is driven When the screw is driven the corrector lever turns counterclockwise with M1 being the fulcrum to move the control sleev...

Page 189: ...installed in the low pressure side The timer piston slides horizontally based on the balance between the spring force and changes in the pump chamber pressure The movement of the timer piston turns th...

Page 190: ...fuel path connected to the inlet port of the plunger barrel When the ignition switch is turned on power is supplied to the magnetic valve to lift the armature thus opening the fuel path On the contrar...

Page 191: ...and damaging the fuel return line fitting Then loosen the high pressure fuel line nuts Figure7 32 3 on the fuel injection pump Finish loosening all the high pressure fuel line nuts and remove the fue...

Page 192: ...hile loosening the V belt Failure to comply may result in minor or moderate injury 9 Remove the cooling fan Figure7 35 1 spacer if equipped Figure7 35 2 and V belt Figure7 35 3 Figure 7 35 10 Remove t...

Page 193: ...rive gear retaining nut Figure7 39 1 and lock washer Figure7 39 2 Figure 7 39 13 Using a two bolt gear puller remove the injection pump drive gear Figure7 39 3 from the injection pump shaft NOTE The i...

Page 194: ...made on the pump drive gear with the mark you made on the idle gear See Figure7 37 Figure 7 41 3 Install the drive gear retaining nut Figure7 42 1 and washer Figure7 42 2 While holding the engine with...

Page 195: ...bolt Figure 7 45 2 that fastens it to the cylinder block Figure 7 45 9 Reinstall the two bolts Figure7 45 1 to the L shaped bracket that holds the injection pump at the bottom rear Tighten the two bol...

Page 196: ...the fuel system and check for leaks Checking Adjustment Of Fuel Injection Timing 1 Using a wrench on the front crankshaft pulley bolt rotate the engine clockwise until the timing mark on the cranksha...

Page 197: ...y is aligned with the mark at 4 6 and 8 5 ATDC After Top Dead Center on the timing grid on the gear case cover 8 5deg ATDC 8 If the injection timing is correct the dial indicator should read 0 038 0 0...

Page 198: ...ump Finish loosening all the high pressure fuel line nuts and remove the fuel lines as an assembly Be careful not to bend any of the fuel lines CAUTION Remove the high pressure fuel injection lines as...

Page 199: ...ng in injury Never inject fuel towards a fire source Atomized fuel is highly flammable and may cause fire or skin burning 4 Pump the operating lever of the tester slowly observing the pressure reading...

Page 200: ...4TNV98 4TNE98 Diesel Engine Section 4 Fuel System 198 Figure 7 54 8 If the fuel injector fails any of these tests it should be repaired or replaced as necessary...

Page 201: ...form Atomization is excessively one sided Although atomized the needle does not pulsate burner like shape Bar shape with excessive after drops Drops bar shape Possible Cause Normal 1 Normally caused b...

Page 202: ...njectors Torque to 29 4ft lb 39 2N m 5 Install the fuel return line fitting using new copper gaskets 6 Tighten the fuel return line retaining nuts to 32 5ft lb 44 1N m CAUTION When loosening or tighte...

Page 203: ...he engine coolant Hot engine coolant may splash and burn you Failure to comply could result in death or serious injury WARNING ENTANGLEMENT HAZARD Stop the engine before you begin to service it NEVER...

Page 204: ...lt in minor or moderate injury CAUTION Only use the engine coolant specified Other engine coolants may affect warranty coverage cause an internal buildup of rust and scale and or shorten engine life P...

Page 205: ...olant pump This engine coolant pump is representative of the coolant pumps used on other TNV model engines For specific part detail see the parts catalog for the engine you are working on Cooling Syst...

Page 206: ...mp Components Figure 8 2 1 Thermostat Cover 2 Thermostat Cover Gasket 3 Thermostat 4 Thermostat O Ring 5 Special O Ring 6 Engine Coolant Pump 7 Temperature Switch 8 Gasket 9 Engine Coolant Pump Gasket...

Page 207: ...e Replace the coolant pump if any of these conditions are present CAUTION If the engine coolant pump must be replaced replace the engine coolant pump as an assembly only Do not attempt to repair the e...

Page 208: ...t of the way CAUTION PINCH HAZARD Carefully rotate the alternator toward the cylinder block while loosening the V belt Failure to comply may result in minor or moderate injury 6 Remove the engine cool...

Page 209: ...8 10 1 and an accurate thermometer Figure 8 10 2 in warm water Figure 8 10 2 Slowly increase the temperature of the water using an external heat source 3 The thermostat is operating properly if it st...

Page 210: ...t Install a new special O ring Figure 8 12 5 on assembly between the engine coolant pump and the joint CAUTION Use a new special O ring between the engine coolant pump and the joint Be sure to use the...

Page 211: ...e the drain cock in the radiator Reinstall and tighten the engine block drain plug or reconnect the coolant hose at the oil cooler 8 Fill the radiator and engine with engine coolant See Drain Flush an...

Page 212: ...and clothing away from moving rotating parts Failure to comply could result in death or serious injury WARNING BURN HAZARD Keep your hands and other body parts away from hot engine surfaces such as th...

Page 213: ...n assembly CAUTION Only use the engine oil specified Other engine oils may affect warranty coverage cause internal engine components to seize and or shorten engine life Prevent dirt and debris from co...

Page 214: ...M At Low Idle Speed 42 57 psi 0 29 0 39 MPa 3 0 4 0 kgf cm All Models 8 8 psi 0 06 MPa 0 6 kfg cm or greater Outer Rotor Outside Clearance All Models Standard Limit Reference Page 0 0039 0 0061 in 0 1...

Page 215: ...0 5108 in 12 955 12 975 mm 0 5096 in 12 945 mm 4TNV98 Rotor Clearance 0 0014 0 0026 in 0 035 0 065 mm 0 0041 in 0 105 mm Check Rotor Shaft Clearance on page 216 Gear Case Bearing I D 0 5110 to 0 5126...

Page 216: ...4TNV98 4TNE98 Diesel Engine Section 6 Lubrication System 214 Lubrication System Diagram Figure 9 1...

Page 217: ...the mechanical oil pressure test gauge indicates good oil pressure replace the faulty oil pressure switch or sending unit or faulty machine oil pressure gauge in instrument panel If the mechanical oil...

Page 218: ...ve the oil pump assembly bolts Remove the oil pump assembly Figure 9 16 1 from the gear case housing Figure 9 16 2 Figure 9 16 Cleaning and Inspection Wash the oil pump oil pressure regulator and oil...

Page 219: ...Figure 9 19 1 Figure 9 19 Record the measurement s and see Check Outer Rotor Side Clearance on page 217 for the service limits Check Rotor Shaft Clearance Determine the rotor shaft clearance Measure...

Page 220: ...22 4 Reinstall the gear case cover and crankshaft pulley See Installation of Gear Case Cover on page 137 5 Reinstall the engine coolant pump V pulley Figure 9 23 1 spacer Figure 9 23 2 engine cooling...

Page 221: ...jewelry tie back long hair and keep your hands other body parts and clothing away from moving rotating parts Failure to comply could result in death or serious injury WARNING SHOCK HAZARD Always read...

Page 222: ...ined total resistance of the battery cable in both directions between the starter motor and the battery is within the value indicated on the wiring diagram The starter motor will malfunction or break...

Page 223: ...ocedures for a representative starter motor For specific part detail see the Yanmar Parts Catalog for the engine you are working on Starter Motor Information No Load Loaded DOOSAN Part Number Mfg Mfg...

Page 224: ...Number of Teeth M3 9 Difference O ring Oil Seal Dry none Application Standard Spring Force 7 868 lbf 35 N 3 6 kgf Standard 0 591 in 15 mm Brush Height Limit 0 354 in 9 mm Series Coil Resistance 0 27 a...

Page 225: ...4TNV98 4TNE98 Diesel Engine Section 7 Starter Motor 223 Starter Motor Troubleshooting...

Page 226: ...mbly 5 Return Spring 6 Pinion Stop 7 Retaining Ring 8 Gear Housing 9 Shift Lever 10 Torsion Spring 11 Plunger 12 Dust Covers Shims 13 Magnetic Switch Assembly Solenoid 14 Cover 15 M6 Bolts 2 used 16 A...

Page 227: ...repair procedures are the same The following procedures are typical and may differ from the stater being serviced Removal of Starter Motor 1 Disconnect the battery cables at the battery negative cabl...

Page 228: ...ce On the positive side remove the brush from the brush holder assembly Figure 11 5 1 Figure 11 5 5 Remove the brush holder assembly Figure 11 6 1 from the armature assembly Figure 11 6 3 Figure 11 6...

Page 229: ...emove the retaining ring Figure 11 10 1 from the shaft of the pinion Figure 11 10 12 Disassemble the pinion stop Figure 11 11 3 return spring Figure 11 11 4 pinion clutch assembly Figure 11 11 1 and p...

Page 230: ...ted in Figure11 14 4 An abnormal commutator condition is indicated in Figure11 14 5 Figure 11 14 See Starter Motor Specifications on page 222 for the service limit Armature Coil Continuity Test Check...

Page 231: ...terminals using a multimeter Figure11 18 The multimeter should indicate continuity If the multimeter does not indicate continuity replace the field coil assembly Figure 11 18 Field Coil Insulation Te...

Page 232: ...g a multimeter Figure11 21 The multimeter should indicate continuity If the multimeter does not indicate continuity replace the magnetic switch Figure 11 21 Series Coil Continuity Test Check for conti...

Page 233: ...ould rotate freely in the drive direction and is locked by turning it in the opposite direction Replace the pinion clutch assembly if the results are different Figure 11 24 Slide the pinion clutch ass...

Page 234: ...and pinion assembly to the gear housing Reinstall and tighten the three M4 bolts 4 Apply a small amount of high temperature lithium grease obtain locally to the sliding portions of the shift lever Fi...

Page 235: ...rough bolts Reconnect the wire to the magnetic switch assembly Tighten the M8 nut Reinstall the cover over the connection Figure 11 32 Check Pinion Projection Length 1 Connect the positive lead from a...

Page 236: ...1 35 5 4 Connect a voltmeter Figure 11 35 7 to the battery negative terminal Figure 11 35 5 and the main positive battery terminal Figure 11 35 3 on the starter motor 5 Install a switch Figure 11 35 6...

Page 237: ...Gauge Set Part No TOL 97190080 Adapter for direct injection 2 valve cylinder head Yanmar Adapter Part No 119802 92950 Adapter for direct injection 4 valve cylinder head for 4TNV94L 98 98T Yanmar Adap...

Page 238: ...on page 147 CAUTION Remove or install the high pressure fuel injection lines as an assembly whenever possible Disassembling the high pressure fuel injection lines from the retainers or bending any of...

Page 239: ...nce Value Compression Pressure at 250 rpm 250 min 1 Engine Model Standard Limit Deviation Between Cylinders 4TNV98 483 513 psi 3 33 3 53 MPa 34 36 kgf cm 384 414 psi 2 65 2 85 MPa 27 29 kgf cm 29 43 p...

Page 240: ...essure at 250 rpm 250 min 1 Engine Model Standard Limit Deviation Between Cylinders 4TNE98 426 15 psi 2 94 0 1 MPa 30 1 kgf cm 341 15 psi 2 35 0 1 MPa 24 1 kgf cm 29 to 43 psi 0 2 to 0 3 MPa 2 to 3 kg...

Page 241: ...the valve clearance Replace the gasket 4 Cylinder Head Gasket Gas leak from gasket Retighten the cylinder head bolts to the specified torque Intake Exhaust Valve Sticking valve Replace the intake exha...

Page 242: ...4TNV98 4TNE98 Diesel Engine Section 8 Troubleshooting 240 Troubleshooting Charts...

Page 243: ...4TNV98 4TNE98 Diesel Engine Section 8 Troubleshooting 241...

Page 244: ...4TNV98 4TNE98 Diesel Engine Section 8 Troubleshooting 242...

Page 245: ...Note The following wiring diagram is representative of a common installation using a Yanmar engine The actual installation may be equipped with a variety of electrical components and wiring harnesses...

Page 246: ...4TNV98 4TNE98 Diesel Engine Section 8 Troubleshooting 244 4TNE98 Engine...

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