Doosan D30S-5 Wartungshandbuch

Service Manual4TNV98 & 4TNE98 Diesel EngineD20S-5, D25S-5, D30S-5, D33S-5, D35C-5(4TNV98 : EM0Q3, EM0Q4, EM0Q5)D20S-5, D25S-5, D30S-5, D33S-5, D35

4TNV98 & 4TNE98 Diesel Engine Section 1. General Service Information 8Location of Labels Figure 4-2 shows the location of regulatory and safet

4TNV98 & 4TNE98 Diesel Engine Section 3. Engine 98Reassembly of Cylinder Head Use new gaskets, O-rings, and seals on reassembly of the cylinder

4TNV98 & 4TNE98 Diesel Engine Section 3. Engine 992. Measure the distance (Figure 6-65, (1)) from the cylinder head to the valve stem seal to en

4TNV98 & 4TNE98 Diesel Engine Section 3. Engine 100Reassembly of Cylinder Head 1. Carefully clean both the combustion surface of the cylinder h

4TNV98 & 4TNE98 Diesel Engine Section 3. Engine 101 Figure 6-68 1) Fan End 2) Camshaft Side Reassembly of Rocker Arm Assembly 4T

4TNV98 & 4TNE98 Diesel Engine Section 3. Engine 102NOTE : To properly align the rocker arm shaft with the rocker arm shaft supports, first reins

4TNV98 & 4TNE98 Diesel Engine Section 3. Engine 103Reassembly of the Valve Cover 1. Lightly grease a new valve cover gasket (Figure 6-73, (6)).

4TNV98 & 4TNE98 Diesel Engine Section 3. Engine 104Measuring and Adjusting Valve Clearance Measure and adjust while the engine is cold. NOTES

4TNV98 & 4TNE98 Diesel Engine Section 3. Engine 1054TNE98 Engine 1. Remove the valve cover. See Removal of Valve Cover on page 103. NOTE : If

4TNV98 & 4TNE98 Diesel Engine Section 3. Engine 1064TNV98 Engine The 4-valve cylinder head operates two valves with a single rocker arm by empl

4TNV98 & 4TNE98 Diesel Engine Section 3. Engine 1077. Tighten the lock nut (Figure 6-80, (1)), while holding the valve bridge (Figure 6-80, (3))

4TNV98 & 4TNE98 Diesel Engine Section 1. General Service Information 9Emission Control Labels Since emission control regulations are being iss

4TNV98 & 4TNE98 Diesel Engine Section 3. Engine 108 Figure 6-83 12. Hold the adjusting screw (Figure 6-83, (4)) while tightening t

4TNV98 & 4TNE98 Diesel Engine Section 3. Engine 109Crankshaft and Camshaft Components Figure 6-

4TNV98 & 4TNE98 Diesel Engine Section 3. Engine 110(1) Cylinder Block. (2) Camshaft Bushing. (3) Gear Case (8) Front Crankshaft Seal.

4TNV98 & 4TNE98 Diesel Engine Section 3. Engine 111Disassembly of Engine Prepare a clean, flat working surface on a workbench large enough to a

4TNV98 & 4TNE98 Diesel Engine Section 3. Engine 112 Figure 6-85 Checking Timing Gear Backlash Prior to removing the timing

4TNV98 & 4TNE98 Diesel Engine Section 3. Engine 113Measuring Idler Gear-to-Camshaft Gear Backlash 1. Drive a small wooden wedge between the cra

4TNV98 & 4TNE98 Diesel Engine Section 3. Engine 114 Figure 6-90 3. Remove the oil pickup tube (Figure 6-91, (1)) and O-r

4TNV98 & 4TNE98 Diesel Engine Section 3. Engine 1152. Remove the two bolts (Figure 6-94, (3)) retaining the camshaft thrust plate (Figure 6-94,

4TNV98 & 4TNE98 Diesel Engine Section 3. Engine 116Disassembly of Crankshaft and Piston Components Removal of Pistons CAUTION Keep the piston

4TNV98 & 4TNE98 Diesel Engine Section 3. Engine 117 IMPORTANT Mark the connecting rod caps and connecting rods so the caps and connecting rods

4TNV98 & 4TNE98 Diesel Engine Section 1. General Service Information 10Function of Major Engine Components Components Functions Air Cleaner Th

4TNV98 & 4TNE98 Diesel Engine Section 3. Engine 118 Figure 6-100 8. Remove the circlips (Figure 6-100, (5)) from the wris

4TNV98 & 4TNE98 Diesel Engine Section 3. Engine 119• Method B : Use a feeler gauge to measure the clearance (Figure 6-103, (3)) between the thru

4TNV98 & 4TNE98 Diesel Engine Section 3. Engine 120 Figure 6-105 IMPORTANT Do not rotate the crankshaft when using PLASTIGAGE. A f

4TNV98 & 4TNE98 Diesel Engine Section 3. Engine 1212. Apply a continuous bead of ThreeBond Liquid Gasket No. 1212 to the outside diameter of a n

4TNV98 & 4TNE98 Diesel Engine Section 3. Engine 122Inspection of Pistons, Piston Rings and Wrist Pin NOTES • On an engine with low hours, the

4TNV98 & 4TNE98 Diesel Engine Section 3. Engine 123 NOTES • On an engine with low hours, the pistons, piston rings and cylinders may be reused

4TNV98 & 4TNE98 Diesel Engine Section 3. Engine 124Inspection of Connecting Rod 1. Measure the wrist pin bushing bore using a bore gauge (Figur

4TNV98 & 4TNE98 Diesel Engine Section 3. Engine 1254. Use the color check method or Magnaflux® to inspect the crankshaft for cracks. Replace the

4TNV98 & 4TNE98 Diesel Engine Section 3. Engine 126 Figure 6-123 Inspection of Camshaft Bushing and Bores 1. Measure the I.D. of t

4TNV98 & 4TNE98 Diesel Engine Section 3. Engine 127 CAUTION Do not allow the honing tool to operate in one position for any length of time. Dama

4TNV98 & 4TNE98 Diesel Engine Section 1. General Service Information 11Function of Cooling System Components Components Functions Cooling Syst

4TNV98 & 4TNE98 Diesel Engine Section 3. Engine 128 Figure 6-127 3. Reinstall one circlip (Figure 6-127, (5)) into the pis

4TNV98 & 4TNE98 Diesel Engine Section 3. Engine 129Piston Assembly When correctly assembled, the piston identification mark (Figure 6-129, (2))

4TNV98 & 4TNE98 Diesel Engine Section 3. Engine 130 IMPORTANT Always use a piston ring installation tool (expander) when installing piston ring

4TNV98 & 4TNE98 Diesel Engine Section 3. Engine 131 Figure 6-70 3. Install one circlip (Figure 6-70, (2)) into the piston.

4TNV98 & 4TNE98 Diesel Engine Section 3. Engine 132 Figure 6-74 • Repeat these steps for the remaining pistons. Installa

4TNV98 & 4TNE98 Diesel Engine Section 3. Engine 1335. Apply a light coat of clean engine oil to the bearing cap bolts and tighten the bolts to t

4TNV98 & 4TNE98 Diesel Engine Section 3. Engine 134 Piston Orientation to Cylinder - By Model Orient the piston identification mark stamped on t

4TNV98 & 4TNE98 Diesel Engine Section 3. Engine 1354TNE98 Engine 1. Lubricate No. 1 piston and piston rings. 2. Using the piston insertion too

4TNV98 & 4TNE98 Diesel Engine Section 3. Engine 136Reassembly of Camshaft and Timing Components Installation of Gear Case or Front Plate 1. If

4TNV98 & 4TNE98 Diesel Engine Section 3. Engine 137 Figure 6-144 (1) Fuel Injection Pump Gea.r (2) Camshaft Gear. (3) Optional Acce

Section 1. Component Identification 12Diesel Fuel Diesel Fuel Specifications Diesel fuel should comply with the following specifications. The tabl

4TNV98 & 4TNE98 Diesel Engine Section 3. Engine 138Installation of Oil Pan 1. Reinstall the oil pickup tube (Figure 6-148, (1)) using a new O-r

4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System 139Section 4. FUEL SYSTEM Before You Begin Servicing WARNING ENTANGLEMENT HAZARD! St

4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System 140 CAUTION NEVER remove or attempt to remove the tamper-proof devices from the full-load f

4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System 1414TNV98 ENGINE Introduction This section of the Service Manual describes the procedure

4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System 142Stop Solenoid The MP fuel injection pumps are equipped with a stop solenoid that contro

4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System 143Fuel System Specifications Special Torque Chart Component Tightening Torque Lubricatin

4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System 144Test and Adjustment Specifications Model Engine Class Injector ID mark*Fuel Injector Pr

4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System 145Special Service Tools No. Tool Name Application Illustration 1 Torque Wrench Locally

4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System 146Fuel System Diagram Figure7-3 (1) Diesel Fuel Tan

4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System 147Fuel System Components 4-Valve Cylinder Head

4TNV98 & 4TNE98 Diesel Engine Section 1. General Service Information 13Precautions and concerns regarding the use of bio-fuels: 1. Free methan

4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System 148Fuel Injection Pump Removal of Fuel Injection Pump 1. Loosen the cooling fan V-belt.

4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System 14912. Separate the stop solenoid wiring connector (Figure 7-8, (2)). 13. Remove the rear f

4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System 15016. To position the fuel injection pump for easier removal and installation, install a d

4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System 15120. Remove the pump drive gear and hub as an assembly using an appropriate two-bolt gear

4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System 152NOTE: The MP4 fuel injection pumps (4TNV98 model engines) are fastened to the gear case

4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System 153To locate the timing index number for the engine being serviced use the Timing Index Char

4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System 1544. Align the key on the fuel injection pump shaft with the keyway in the fuel injection

4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System 155• Calculate the difference between the timing index numbers (Figure 7-26, (1)) of the fue

4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System 1566. Reinstall the rear bracket(s) (Figure 7-29, (1)) to the fuel injection pump. Tighten

4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System 157 Figure 7-31 13. Reinstall the coolant pump V-pulley (Figure 7-32, (4)

4TNV98 & 4TNE98 Diesel Engine Section 1. General Service Information 14 DANGER FIRE AND EXPLOSION HAZARD! Diesel fuel is flammable and explo

4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System 1582. Using the FIR number for the engine being serviced use the Fuel Injection Reference (

4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System 159 Figure 7-37 5. Install a dial indicator (Figure 7-38, (1)), Mitutoyo N

4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System 160NOTE: The TDC (Top Dead Center) mark can be identified by the cylinder numbers stamped n

4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System 16110. Rotate the crankshaft counter-clockwise until the dial indicator shows that the injec

4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System 1623. Note the reading on the dial indicator (Figure 7-44, (1)). If the reading is less tha

4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System 163Fuel Injectors Removal of Fuel Injectors 4-Valve Cylinder Head 1. Close any fuel valve

4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System 164Testing of Fuel Injectors CAUTION Never use a steel wire brush to clean fuel injectors.

4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System 1656. Pump the operating lever more rapidly to repeatedly “pop” the injector and observe the

4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System 1665. Turn the injector over and remove the nozzle body, nozzle valve, valve stop spacer, n

4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System 167See the parts catalog for available shims. CAUTION Each pressure adjusting shim removed

4TNV98 & 4TNE98 Diesel Engine Section 1. General Service Information 15Priming the Fuel System The fuel system needs to be primed under certai

4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System 1684TNE98 ENGINE Fuel System Special Torque Chart Component Tightening Torque Lubricating

4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System 169Fuel System Components Figure 7-1

4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System 170Fuel System Components Figure 7-2 Fuel is fed from t

4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System 171Structure And Operation Of Fuel Injection Pump Figure 7-3

4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System 172Overview Pump Figure 7-4 The drive shaft directly receives the engine

4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System 173Timer Figure 7-6 At the bottom of the injection pump is the built-in t

4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System 174Regulating Valve Figure 7-8 The regulating valve regulates the fuel f

4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System 175Plunger Operation Figure 7-3 The drive shaft simultaneou

4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System 176Process Suction Process Figure 7-10 Figure 7-11 Whe

4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System 177End of Injection Figure 7-14 Figure 7-15 When the plunger

4TNV98 & 4TNE98 Diesel Engine Section 1. General Service Information 16Engine Oil CAUTION Only use the engine oil specified. Other engine o

4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System 178Reverse Rotation Prevention Mechanism Figure 7-18 While the plunger is r

4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System 179Delivery Valve Assembly Figure 7-20 The delivery valve assemb

4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System 180All - Speed Governor Figure 7-22 Figure7-22 shows the compo

4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System 181The start and tension levers contact each other and move together during engine operation

4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System 182At Start of Engine Figure 7-25 It is necessary to incre

4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System 183During Idling Figure 7-26 When the engine starts and the

4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System 184At Full-Load Maximum Speed Control Figure 7-27 When the

4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System 185At No-Load Maximum Speed Control Figure 7-28 When the en

4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System 186Full-Load Position Adjustment Mechanism Figure 7-29 The full-load

4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System 187Structure And Operation Of Timer The ignition period which occurs in the combustion proc

4TNV98 & 4TNE98 Diesel Engine Section 1. General Service Information 17Checking Engine Oil 1. Make sure the engine is level. 2. Remove the di

4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System 188Magnetic Valve (Stop Solenoid) Figure 7-31 The magnetic valve (stop so

4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System 189Removal Of Fuel Injection Pump 1. Remove fuel supply line from the fuel injection pump.

4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System 190 Figure 7-34 • Loosen the bolt (Figure7-34, (2)) that fastens the r

4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System 191 CAUTION Do not rotate the engine with the injection pump removed. Figure

4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System 192Installation Of The Fuel Injection Pump 1. Secure the fuel injection pump mounting flan

4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System 193 Figure 7-43 5. Reinstall the cooling fan (Figure7-44, (1)), spacer

4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System 194 Figure 7-46 11. Reconnect the throttle linkage. 12. Reconnect

4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System 1954. Install Yanmar timing tool (Figure7-49, (1)), into the port where the bolt was removed

4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System 196Servicing The Fuel Injectors Removal of the Fuel Injectors 1. Remove the high pressure

4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System 197Inspection and Testing of the Fuel Injectors Visually inspect the fuel injectors and noz

4TNV98 & 4TNE98 Diesel Engine Section 1. General Service Information 18Engine Coolant DANGER SCALD HAZARD! NEVER remove the radiator cap

4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System 198 Figure 7-54 8. If the fuel injector fails any of these tests, it should

4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System 199Judgement Criteria on Atomization Condition A B C D E Injection Pattern Pres

4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System 200Cleaning of Nozzle 1. Clean the exterior of the nozzle, taking care not to damage the n

4TNV98 & 4TNE98 Diesel Engine Section 5. Cooling System 201Section 5. COOLING SYSTEM Before You Begin Servicing DANGER SCALD HAZARD! NEV

4TNV98 & 4TNE98 Diesel Engine Section 5. Cooling System 202 WARNING BURN HAZARD! If you must drain the engine oil while it is still hot, stay

4TNV98 & 4TNE98 Diesel Engine Section 5. Cooling System 203Introduction This section of the Service Manual describes the procedures necessary

4TNV98 & 4TNE98 Diesel Engine Section 5. Cooling System 204Engine Coolant Pump Components Figure 8-2

4TNV98 & 4TNE98 Diesel Engine Section 5. Cooling System 205Engine Coolant System Check Check the engine coolant system for leakage. 1. With t

4TNV98 & 4TNE98 Diesel Engine Section 5. Cooling System 206• On models not equipped with an oil cooler, remove the coolant drain plug (Figure 8-6

4TNV98 & 4TNE98 Diesel Engine Section 5. Cooling System 207Disassembly of Engine Coolant Pump 1. Remove the thermostat cover (Figure 8-8, (1))

4TNV98 & 4TNE98 Diesel Engine Section 1. General Service Information 19Engine Coolant Specifications Use a Long Life Coolant (LLC) or an Exten

4TNV98 & 4TNE98 Diesel Engine Section 5. Cooling System 208Reassembly of Engine Coolant Pump 1. Reinstall the thermostat (Figure 8-12, (1)) and

4TNV98 & 4TNE98 Diesel Engine Section 5. Cooling System 2095. Inspect the condition of the V-belt. There must be clearance (Figure 8-14, (1)) b

4TNV98 & 4TNE98 Diesel Engine Section 6. Lubrication System 210Section 6. LUBRICATION SYSTEM Before You Begin Servicing WARNING ENTANGL

4TNV98 & 4TNE98 Diesel Engine Section 6. Lubrication System 211 CAUTION FLYING OBJECT HAZARD! ALWAYS wear eye protection when servicing the

4TNV98 & 4TNE98 Diesel Engine Section 6. Lubrication System 212Introduction This section of the Service Manual describes the procedures necessar

4TNV98 & 4TNE98 Diesel Engine Section 6. Lubrication System 213Rotor Shaft Clearance Model Inspection Item Standard Limit Reference Page Gear C

4TNV98 & 4TNE98 Diesel Engine Section 6. Lubrication System 214Lubrication System Diagram Figure 9-1

4TNV98 & 4TNE98 Diesel Engine Section 6. Lubrication System 215Checking Engine Oil Pressure Perform an engine oil pressure check if there is any

4TNV98 & 4TNE98 Diesel Engine Section 6. Lubrication System 216Disassembly of Oil Pump CAUTION If the oil pump must be replaced, replace it as

4TNV98 & 4TNE98 Diesel Engine Section 6. Lubrication System 217Outer Rotor to Inner Rotor Tip Clearance Determine the outer rotor to inner rotor

4TNV98 & 4TNE98 Diesel Engine Section 1. General Service Information 20 Figure 4-8 2. Remove the radiator cap (Figure 4-6, (2

4TNV98 & 4TNE98 Diesel Engine Section 6. Lubrication System 2183. Reinstall the oil pump assembly (Figure 9-22, (1)) into the gear case housing

4TNV98 & 4TNE98 Diesel Engine Section 7. Starter Motor 219Section 7. STARTER MOTOR Before You Begin Servicing WARNING ENTANGLEMENT HAZARD

4TNV98 & 4TNE98 Diesel Engine Section 7. Starter Motor 220 CAUTION FLYING OBJECT HAZARD! ALWAYS wear eye protection when servicing the engi

4TNV98 & 4TNE98 Diesel Engine Section 7. Starter Motor 221Introduction This section of the Service Manual covers the servicing of the starter

4TNV98 & 4TNE98 Diesel Engine Section 7. Starter Motor 222Starter Motor Specifications DOOSAN Part Number A408417 Nominal Output 3.0 hp (2.3

4TNV98 & 4TNE98 Diesel Engine Section 7. Starter Motor 223Starter Motor Troubleshooting

4TNV98 & 4TNE98 Diesel Engine Section 7. Starter Motor 224Starter Motor Components Figure 11-1 (1) Pinio

4TNV98 & 4TNE98 Diesel Engine Section 7. Starter Motor 225Starter Motor WARNING SHOCK HAZARD! Turn off the battery switch (if equipped) o

4TNV98 & 4TNE98 Diesel Engine Section 7. Starter Motor 226 Figure 11-4 3. Remove the two M5 through bolts (Figure 11-4, (4)). S

4TNV98 & 4TNE98 Diesel Engine Section 7. Starter Motor 2279. Remove the three M4 bolts (Figure 11-9, (1)) securing the bearing retainer assembl

4TNV98 & 4TNE98 Diesel Engine Section 1. General Service Information 21Engine General Specifications Type Vertical In-line, Water Cooled, 4-Cy

4TNV98 & 4TNE98 Diesel Engine Section 7. Starter Motor 228 Figure 11-13 See Starter Motor Specifications on page 222 for the service

4TNV98 & 4TNE98 Diesel Engine Section 7. Starter Motor 229Measure Armature and Commutator Run-Outs Measure the armature core run-out and the c

4TNV98 & 4TNE98 Diesel Engine Section 7. Starter Motor 230Magnetic Switch If the starter motor becomes wet, replace the magnetic switch even if

4TNV98 & 4TNE98 Diesel Engine Section 7. Starter Motor 231Contact Continuity Test Depress the plunger at the bottom of the magnetic switch. Ch

4TNV98 & 4TNE98 Diesel Engine Section 7. Starter Motor 232Reassembly of Starter Motor 1. Apply the appropriate starter bendix grease (obtain lo

4TNV98 & 4TNE98 Diesel Engine Section 7. Starter Motor 2338. Position the brush springs in brush holders (Figure 11-31). Reinstall the brushes

4TNV98 & 4TNE98 Diesel Engine Section 7. Starter Motor 234No-Load Test Test the characteristics of the starter motor by performing a no-load te

4TNV98 & 4TNE98 Diesel Engine Section 8. Troubleshooting 235Section 8. TROUBLESHOOTING Special Service Tools For measuring compression pressur

4TNV98 & 4TNE98 Diesel Engine Section 8. Troubleshooting 236Troubleshooting By Measuring Compression Pressure Compression pressure drop is one

4TNV98 & 4TNE98 Diesel Engine Section 8. Troubleshooting 237Standard Compression Pressure (Reference Value) Compression Pressure at 250 rpm (25

4TNV98 & 4TNE98 Diesel Engine Section 1. General Service Information 22Principal Engine Specifications 4TNV98 EPA Tier 2 Engine Model 4T

4TNV98 & 4TNE98 Diesel Engine 238 Section 8. Troubleshooting Compression Pressure at 250 rpm (250 min-1) Engine Model Standard Limit Deviation

4TNV98 & 4TNE98 Diesel Engine Section 8. Troubleshooting 239Measured Value and Troubleshooting When the measured compression pressure is below

4TNV98 & 4TNE98 Diesel Engine Section 8. Troubleshooting 240Troubleshooting Charts

4TNV98 & 4TNE98 Diesel Engine Section 8. Troubleshooting 241

4TNV98 & 4TNE98 Diesel Engine Section 8. Troubleshooting 242

4TNV98 & 4TNE98 Diesel Engine Section 8. Troubleshooting 243Wiring Diagram Note: The following wiring diagram is “representative” of a common i

4TNV98 & 4TNE98 Diesel Engine Section 8. Troubleshooting 2444TNE98 Engine

4TNV98 & 4TNE98 Diesel Engine Section 1. General Service Information 234TNE98 EPA Tier 3 Engine Model 4TNE98 EPA Tier 3 Version VM (BQDF(C

4TNV98 & 4TNE98 Diesel Engine Section 1. General Service Information 24Engine Service Standards Inspection Item Standard Limit Reference pag

4TNV98 & 4TNE98 Diesel Engine Section 1. General Service Information 25Tightening Torques for Standard Bolts and Nuts Use the correct amount o

4TNV98 & 4TNE98 Diesel Engine Section 1. General Service Information 26 Item Nominal Thread Diameter x Pitch Tightening Torque Remarks M6 x 1.

4TNV98 & 4TNE98 Diesel Engine Section 1. General Service Information 27Abbreviations and Symbols Abbreviations. A ampere AC alternating cur

1 Important Safety Information Most accidents involving product operation, maintenance and repair are caused by failure to observe basic safety rul

4TNV98 & 4TNE98 Diesel Engine Section 1. General Service Information 28Unit Conversions Unit Prefixes Prefix Symbol Power mega M x 1,000

4TNV98 & 4TNE98 Diesel Engine Section 2. Periodic Maintenance 29Section 2. PERIODIC MAINTENANCE Before You Begin Servicing DANGER EXPLOSI

4TNV98 & 4TNE98 Diesel Engine Section 2. Periodic Maintenance 30 DANGER FIRE AND EXPLOSION HAZARD! Diesel fuel is flammable and explosive und

4TNV98 & 4TNE98 Diesel Engine Section 2. Periodic Maintenance 31 DANGER CRUSH HAZARD! When you need to transport an engine for repair, have

4TNV98 & 4TNE98 Diesel Engine Section 2. Periodic Maintenance 32 WARNING EXHAUST HAZARD! NEVER operate the engine in an enclosed area such as

4TNV98 & 4TNE98 Diesel Engine Section 2. Periodic Maintenance 33 WARNING SUDDEN MOVEMENT HAZARD! Engaging the transmission or PTO at an elevat

4TNV98 & 4TNE98 Diesel Engine Section 2. Periodic Maintenance 34 WARNING EXPOSURE HAZARD! Wear personal protective equipment such as gloves

4TNV98 & 4TNE98 Diesel Engine Section 2. Periodic Maintenance 35 WARNING SHOCK HAZARD! Turn off the battery switch (if equipped) or discon

4TNV98 & 4TNE98 Diesel Engine Section 2. Periodic Maintenance 36 CAUTION COOLANT HAZARD! Wear eye protection and rubber gloves when you hand

4TNV98 & 4TNE98 Diesel Engine Section 2. Periodic Maintenance 37 CAUTION Observe the following environmental operating conditions to maintain e

4TNV98 & 4TNE98 Diesel Engine Section 2. Periodic Maintenance 38 CAUTION New Engine Break-in: • On the initial engine start-up, allow the engine

4TNV98 & 4TNE98 Diesel Engine Section 2. Periodic Maintenance 39 CAUTION NEVER use high-pressure water or compressed air at greater than 28 psi

4TNV98 & 4TNE98 Diesel Engine Section 2. Periodic Maintenance 40Introduction This section of the Service Manual describes the procedures for pro

4TNV98 & 4TNE98 Diesel Engine Section 2. Periodic Maintenance 41Periodic Maintenance Schedule Daily and periodic maintenance is important to k

4TNV98 & 4TNE98 Diesel Engine Section 2. Periodic Maintenance 42○:Check ◇:Replace Periodic Maintenance Interval System Check Item DailyEvery50

4TNV98 & 4TNE98 Diesel Engine Section 2. Periodic Maintenance 43Periodic Maintenance Procedures Daily Perform the following procedures daily.

4TNV98 & 4TNE98 Diesel Engine Section 2. Periodic Maintenance 44 CAUTION Be responsible to the environment. Follow these procedures for ha

4TNV98 & 4TNE98 Diesel Engine Section 2. Periodic Maintenance 45Daily After Initial 50 Hours of Operation Perform the following maintenance

4TNV98 & 4TNE98 Diesel Engine Section 2. Periodic Maintenance 46The engine oil in a new engine becomes contaminated from the initial break-in of

4TNV98 & 4TNE98 Diesel Engine Section 2. Periodic Maintenance 474. Add new engine oil to the engine as specified in Adding Engine Oil on page 1

4TNV98 & 4TNE98 Diesel Engine 3 Index Section 1. GENERAL SERVICE INFORMATION Component Identification ...7 L

4TNV98 & 4TNE98 Diesel Engine Section 2. Periodic Maintenance 482. If necessary, adjust the V-belt tension. Loosen the adjusting bolt (Figure 5-

4TNV98 & 4TNE98 Diesel Engine Section 2. Periodic Maintenance 49 CAUTION If the fuel filter / water separator is positioned higher than the fu

4TNV98 & 4TNE98 Diesel Engine Section 2. Periodic Maintenance 50Check Battery DANGER EXPLOSION HAZARD! NEVER check the remaining battery

4TNV98 & 4TNE98 Diesel Engine Section 2. Periodic Maintenance 51If operating the machine where the ambient temperature could drop to 5°F (-15°C

4TNV98 & 4TNE98 Diesel Engine Section 2. Periodic Maintenance 52Check and Clean Radiator Fins CAUTION FLYING OBJECT HAZARD! ALWAYS wear

4TNV98 & 4TNE98 Diesel Engine Section 2. Periodic Maintenance 53Checking and adjusting the governor lever: 1. Check that the governor lever

4TNV98 & 4TNE98 Diesel Engine Section 2. Periodic Maintenance 543. Blow air (Figure 5-12, (3)) through the element from the inside out using 42-

4TNV98 & 4TNE98 Diesel Engine Section 2. Periodic Maintenance 55Change the engine oil every 250 hours of operation after the initial change at

4TNV98 & 4TNE98 Diesel Engine Section 2. Periodic Maintenance 56 Figure 5-14 4. Clean the filter mounting surface and apply a sma

4TNV98 & 4TNE98 Diesel Engine Section 2. Periodic Maintenance 5710. Remove the fuel filter sensor assembly (Figure 5-15, (5)) by turning it to

4TNV98 & 4TNE98 Diesel Engine 4 Index Measuring Instruments...77 Cylinder Head...

4TNV98 & 4TNE98 Diesel Engine Section 2. Periodic Maintenance 58 CAUTION ALWAYS be environmentally responsible. Follow the guidelines of t

4TNV98 & 4TNE98 Diesel Engine Section 2. Periodic Maintenance 59Every 1000 Hours of Operation Perform the following maintenance every 1000 hou

4TNV98 & 4TNE98 Diesel Engine Section 2. Periodic Maintenance 60 Figure 5-16 4. Drain the coolant from the engine block. • On

4TNV98 & 4TNE98 Diesel Engine Section 2. Periodic Maintenance 61Every 1500 Hours of Operation Perform the following maintenance every 1500 hou

4TNV98 & 4TNE98 Diesel Engine Section 2. Periodic Maintenance 62Failure of the diaphragm and / or spring will cause the loss of pressure control

Section 3. Engine 63Section 3. ENGINE Before You Begin Servicing WARNING To prevent possible eye injury, always wear SAFETY GLASSES whil

4TNV98 & 4TNE98 Diesel Engine Section 3. Engine 64 CAUTION Only use the engine oil specified. Other engine oils may affect warranty coverage, ca

4TNV98 & 4TNE98 Diesel Engine Section 3. Engine 65 CAUTION Keep the piston pin parts, piston assemblies, and connecting rod assemblies together

4TNV98 & 4TNE98 Diesel Engine Section 3. Engine 66Introduction This section of the Service Manual describes servicing of the engine. Cy

4TNV98 & 4TNE98 Diesel Engine Section 3. Engine 67Intake / Exhaust Valve and Guide Cont 4TNV98 Engine Inspection Item Standard Limit Referenc

4TNV98 & 4TNE98 Diesel Engine 5 Index Section 5. COOLING SYSTEM Before You Begin Servicing...201 Introduction...

4TNV98 & 4TNE98 Diesel Engine Section 3. Engine 68Push Rod Inspection Item Standard Limit Reference Page Page Push Rod Bend Less than 0.0012 i

4TNV98 & 4TNE98 Diesel Engine Section 3. Engine 69(Camshaft Cont.) Inspection Item Standard Limit Reference Page Bushing Inside Diameter 1.96

4TNV98 & 4TNE98 Diesel Engine Section 3. Engine 70Crankshaft and Piston Specifications Crankshaft NOTE : Check appropriate parts catalog for v

4TNV98 & 4TNE98 Diesel Engine Section 3. Engine 71Piston Inspection Item Standard Limit Reference Page Piston Outside Diameter (Measure at 90

4TNV98 & 4TNE98 Diesel Engine Section 3. Engine 72Connecting Rod Connecting Rod Small End Inspection Item Standard Limit Reference Page Wr

4TNV98 & 4TNE98 Diesel Engine Section 3. Engine 73Cylinder Block Specifications Cylinder Block Inspection Item Standard Limit Reference Pag

4TNV98 & 4TNE98 Diesel Engine Section 3. Engine 74(Torque for Bolts and Nuts Cont.) Component Thread Diameter and Pitch Torque Lubricating Oil

4TNV98 & 4TNE98 Diesel Engine Section 3. Engine 75Special Service Tools No. Tool Name Applicable Model and Tool Size Illustration Model L1

4TNV98 & 4TNE98 Diesel Engine Section 3. Engine 76(Special Service Tools Cont.) No. Tool Name Applicable Model and Tool Size Illustration 7

4TNV98 & 4TNE98 Diesel Engine Section 3. Engine 77Measuring Instruments No. Instrument Name Application Illustration 1 Dial Indicator Local

4TNV98 & 4TNE98 Diesel Engine Section 3. Engine 78 No. Instrument Name Application Illustration 9 V-Block Locally Available For measuring s

4TNV98 & 4TNE98 Diesel Engine Section 3. Engine 79 No. Instrument Name Application Illustration 15 Circuit Tester For measuring resistance, vo

4TNV98 & 4TNE98 Diesel Engine Section 3. Engine 80Cylinder Head Cylinder Head Components 4TNV98 Engine

4TNV98 & 4TNE98 Diesel Engine Section 3. Engine 81(1) Crankcase Breather Cover. (2) Diaphragm Spring. (3) Diaphragm Cup. (4) Crankcase

4TNV98 & 4TNE98 Diesel Engine Section 3. Engine 82Disassembly of 4-Valve Cylinder Head Prepare a clean, flat working surface on a workbench lar

4TNV98 & 4TNE98 Diesel Engine Section 3. Engine 83 Figure 6-38 10. Remove the engine coolant pump. See Disassembly of Engine Co

4TNV98 & 4TNE98 Diesel Engine Section 3. Engine 84Removal of Rocker Arm Assembly 1. Remove the fuel injectors from the cylinder head. See Remov

4TNV98 & 4TNE98 Diesel Engine Section 3. Engine 85Removal of Cylinder Head 1. Loosen the cylinder head bolts following the sequence shown in (F

4TNV98 & 4TNE98 Diesel Engine Section 3. Engine 863. Remove the valve keepers (Figure 6-46, (1)). 4. Slowly release the tension on the valve s

4TNV98 & 4TNE98 Diesel Engine Section 3. Engine 87 4TNE98 Engine Figure 6-

4TNV98 & 4TNE98 Diesel Engine Section 1. General Service Information 7Section 1. GENERAL SERVICE INFORMATION Component Identification Figure

4TNV98 & 4TNE98 Diesel Engine Section 3. Engine 88(1) Valve Cover Nut (2) Valve Cover Nut O-ring (3) Valve Cover (4) V

4TNV98 & 4TNE98 Diesel Engine Section 3. Engine 89Disassembly of Cylinder Head Prepare a clean, flat working surface on a workbench large enoug

4TNV98 & 4TNE98 Diesel Engine Section 3. Engine 90 Figure 6-4 3. Remove the valve cover (Figure 6-4, (3)). Discard the valve co

4TNV98 & 4TNE98 Diesel Engine Section 3. Engine 91 Figure 6-7 4. .If necessary, remove the valve adjusting screw (Figure 6-7, (

4TNV98 & 4TNE98 Diesel Engine Section 3. Engine 924. Slowly release the tension on the valve spring. 5. Remove the spring retainer (Figure 6-11

4TNV98 & 4TNE98 Diesel Engine Section 3. Engine 93Thoroughly clean all components using a non-metallic brush and an appropriate solvent. Each pa

4TNV98 & 4TNE98 Diesel Engine Section 3. Engine 94 Figure 6-49 Rocker Arm Shaft Outside Diameter Use a micrometer to measure the

4TNV98 & 4TNE98 Diesel Engine Section 3. Engine 95If distortion exceeds the service limit, resurface or replace the cylinder head. Remove only e

4TNV98 & 4TNE98 Diesel Engine Section 3. Engine 96 Figure 6-56 Valve Face and Valve Seat Always check the clearance between the

4TNV98 & 4TNE98 Diesel Engine Section 3. Engine 97Grind the valve face and/or valve seat as necessary to return them to serviceable condition. G