Yanmar 4TNV98 Service Manual

Contents

4TNV98 & 4TNE98 Diesel Engine 3 IndexSection 1. GENERAL SERVICEINFORMATIONComponent Identification ...................................... 7Location of Labels................................................. 8Engine Nameplate (Typical)...................... 8Emission Control Regulations ............................... 8EPA / ARB Regulations - USA Only........... 8Emission Control Labels ....................................... 9The 97/68/EC Directive Certified Engines.............. 9Engine Family....................................................... 9Function of Major Engine Components................ 10Function of Cooling System Components............ 11Diesel Fuel.......................................................... 12Diesel Fuel Specifications....................... 12Filling The Fuel Tank .............................. 13Priming the Fuel System......................... 15Engine Oil........................................................... 16Engine Oil Specifications ........................ 16Engine Oil Viscosity................................ 16Checking Engine Oil ............................... 17Adding Engine Oil................................... 17Engine Oil Capacity (Typical).................. 17Engine Coolant ................................................... 18Engine Coolant Specifications ................ 19Filling Radiator with Engine Coolant ....... 19Engine Coolant Capacity (Typical) .......... 20Specifications...................................................... 20Description of Model Number ................. 20Engine General Specifications ................ 21Principal Engine Specifications............................ 224TNV98 EPA Tier 2 .............................. 224TNE98 EPA Tier 3 .............................. 23Engine Service Standards................................... 24Tightening Torques for Standard Bolts and Nuts .. 25Abbreviations and Symbols................................. 27Abbreviations. ........................................ 27Symbols ................................................. 27Unit Conversions ................................................ 28Unit Prefixes........................................... 28Units of Length ....................................... 28Units of Volume ...................................... 28Units of Mass ......................................... 28Units of Force......................................... 28Units of Torque ....................................... 28Units of Pressure.................................... 28Units of Power........................................ 28Units of Temperature .............................. 28Section 2. PERIODIC MAINTENANCEBefore You Begin Servicing ................................ 29Introduction ........................................................ 40The Importance of Periodic Maintenance 40Performing Periodic Maintenance........... 40Yanmar Replacement Parts.................... 40Required EPA / ARB Maintenance-USA Only.............................................................. 40EPA / ARB Installation Requirements-USAOnly....................................................... 40Periodic Maintenance Schedule.......................... 41Periodic Maintenance Procedures ...................... 43Drain Fuel Filter / Water Separator ......... 434TNE98 For D25S-5 Only ...................... 43Daily................................................................... 45After Initial 50 Hours of Operation........... 45Every 50 Hours of Operation .................. 48Every 250 Hours of Operation ................ 51Every 500 Hours of Operation ................ 54Every 1000 Hours of Operation .............. 59Every 1500 Hours of Operation .............. 61Every 2000 Hours of Operation .............. 62Section 3. ENGINEBefore You Begin Servicing ................................ 63Introduction ........................................................ 66Cylinder Head Specifications .............................. 66Adjustment Specifications ...................... 66Cylinder Head ........................................ 66Intake / Exhaust Valve and Guide Cont... 67Push Rod............................................... 68Rocker Arm and Shaft ............................ 68Valve Spring........................................... 68Camshaft and Timing Gear Train Specifications .. 68Camshaft ............................................... 68Idler Gear Shaft and Bushing ................. 69Timing Gear Backlash ............................ 69Crankshaft and Piston Specifications .................. 70Crankshaft ............................................. 70Thrust Bearing ....................................... 70Piston .................................................... 71Connecting Rod ..................................... 72Tappet.................................................... 72Cylinder Block Specifications .............................. 73Cylinder Block........................................ 73Special Torque Chart .......................................... 73Torque for Bolts and Nuts ....................... 73Special Service Tools.......................................... 75