Yanmar 4TNV98 4TNV98T Engine - Service Manual - Repair Manual

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YANMAR 4TNV98, 4TNV98T ENGINE - WORKSHOP, SERVICE, REPAIR MANUAL

- English Service Manual / Repair Manual, for Yanmar 4TNV98 4TNV98T Engine.
 

CONTENTS:

GENERAL  
- Engine Nomenclature  
- Specifications  
- Fuel Oil, Lubricating Oil and Cooling Water  
- Fuel oil  
- Lubricating oil    
- Cooling water  
- Engine External Views  
- Structural Description  
- Exhaust gas emission regulation  
- The Emission Standard in USA  
- Engine identification  
- Guarantee Conditions for the EPA Emission Standard  
INSPECTION AND ADJUSTMENT  
- Periodic Maintenance Schedule  
- Periodic Inspection and Maintenance Procedure  
- Check before Daily Operation  
- Adjusting the no-load maximum or minimum speed  
- Sensor Inspection  
- Oil pressure switch  
- Thermo switch  
- Water leak check in cooling water system   
- Radiator cap inspection  
- Thermostat Inspection  
- Adjusting Operation  
- Long storage  
TROUBLESHOOTING  
- Preparation before troubleshooting  
- Quick Reference Table for Troubleshooting  
- Troubleshooting by measuring Compression Pressure  
DISASSEMBLY, INSPECTION AND REASSEMBLY OF ENGINES  
- Complete disassembly and reassembly  
- Introduction  
- Special service tools  
- Complete disassembly  
- Precautions before and during reassembly  
- Adjusting operation  
- Cylinder Head Disassembly, Inspection and Reassembly  
- Components (-valve cylinder head)  
- Disassembly procedure  
- Reassembly procedure  
- Servicing points  
- Parts Inspection and measurement  
- Valve seat correction  
- Valve guide replacement  
- Valve stem seal replacement  
- Gear Train and Camshaft  
- Components  
- Disassembly procedure  
- Reassembly procedure      
- Servicing points  
- Parts inspection and measurement  
- Oil seal replacement (Gear case side)  
- Camshaft bushing replacement  
- Cylinder Block    
- Components  
- Disassembly procedure  
- Reassembly procedure  
- Servicing points  
- Parts inspection and measurement  
- Cylinder bore correction    
- Piston pin bushing replacement  
- Oil seal replacement (Flywheel housing side)  
LUBRICATION SYSTEM  
- Lubrication System Diagram  
- Trochoid Pump Components  
- Disassembly( Reverse the procedure below for assembly)  
- Servicing Points  
- Parts Inspection and Measurement  
- Trochoid pump inspection and measurement  
- COOLING SYSTEM  
- Cooling Water System  
- Cooling Water Pump Components  
- Disassembly (Reverse the procedure below for assembly)  
- Servicing Points  
FUEL INJECTION PUMP/GOVERNOR  
- Introduction  
- Fuel Injection Pump    
- Fuel system diagram
- External view and components  
- Disassembly procedure  
- Assembly procedure  
- Servicing points  
TURBOCHAGER
- Disassembly, inspection and reassembly  
- Structure and Functions  
- Main specifications  
- Construction  
- Structural and functional outline    
- Components  
- Service Standards and Tightening Torque  
- Service standards  
- Tightening torque  
- Periodic Inspection Procedure   
- Periodic inspection intervals  
- Inspection procedure  
- Waste gate valve adjustment procedure  
- Disassembly Procedure  
- Preparation for disassembly  
- Inspection before disassembly  
- Disassembly  
- Washing and Inspection procedure  
- Washing  
- inspection procedure  
- Reassembly Procedure  
- Preparation for reassembly  
- Reassembly  
- Handling after Disassembly and Reassembly  
- Instructions for turbocharger installation  
- Troubleshooting  
- Excessively exhaust smoke  
- White smoke generation  
- Sudden oil decrease  
- Decrease in output  
- Poor (slow) response (starting) of turbocharger  
- Abnormal sound or vibration  
STARTING MOTOR  
- ForTNVU  
- Specifications  
- Components  
- Troubleshooting  
- Names of parts and disassembly procedure  
- Inspection and Maintenance  
- Service standards  
- Assembly  
- Characteristic test  
- For TNV(T)      
- Specifications  
- Congiguration drawing  
- Troubleshooting  
- Component names and disassembly procedure  
- Disassembly procedure   
- Inspection and maintenance  
- Assembly  
- Adjustment    
- Service standards  
ALTERNATOR  
- The A Alternator for TNV and other models  
- Components  
- Specifications    
- Wiring diagram  
- Standard output characteristics  
- Inspection  
- Troubleshooting    
ELECTRIC WIRING  
- Electric Wiring Diagram  
PRECAUTION ON ELECTRIC WIRING  
- Alternator  
- Starter  
- Current limiter  
- Section area and resistance of electric wire  
SERVICE STANDARDS  
- Engine Tuning  
- Engine Body  
- Cylifder head    
- Gear train and camshaft  
- Cylinder block  
- Lubricating Oil System (Trochoid Pump)  
- Outside clearance of outer rotor  
- Side clearance of outer rotor  
- Inside clearance of inner rotor  
- Rotor shaft clearance  
- TIGHTENING TORQUE FOR BOLTS AND NUTS  
- Tightening Torques for Main Bolts and Nuts  
- Tightening Torques for Standard Bolts and Nuts