Page 1 WEBMTNV000 SHOP MANUAL 3D82AE SERIES 3D84E SERIES 3D88E SERIES 4D88E SERIES 4D98E SERIES 4D106 SERIES S4D84E SERIES S4D98E SERIES S4D106 SERIES DIESEL ENGINE...
Page 2 WEBMTNV000 SHOP MANUAL ENGINE MODEL APPLICABLE MACHINE MODEL KOMATSU DESCRIPTION YANMAR DESCRIPTION PC27R-8 3TNV82A-M5FA 3D82AE-5MFA PC35R-8 3TNV88-N5FA 3D88E-5NFA PC45R-8 4TNV88-N5FA 4D88E-5NFA PC75R-2 4TNV98-X2FB 4D98E-2XFB PW75R-2 4TNV98-X2FB 4D98E-2XFB PC95R-2 4TNV106-S2FB 4D106-2SFB PW95R-2 4TNV106-S2FB 4D1062SFB PC110R-1 4TNV106T-W2FB S4D106-2WFB PW110R-1 4TNV106T-W2FB S4D106-2WFB SK510-5...
Page 3 PREFACE This manual describes the service procedures for the TNV series engines of indirect injection system that have been certified by the US EPA, California ARB and/or the 97/68/EC Directive for industrial use. Please use this manual for accurate, quick and safe servicing of the said engine. Since the explanation in this manual assumes the standard type engine, the specifications and components may partially be different from the engine installed on individual work equipment (power generator, pump, compressor, etc.).
Page 4 SAFETY LABELS Most accidents are caused by negligence of basic safety rules and precautions. For accident prevention, it is important to avoid such causes before development to accidents. Please read this manual carefully before starting repair or maintenance to fully understand safety precautions and appropriate inspection and maintenance procedures.
Page 5 Safety Precautions (1) SERVICE AREA Sufficient Ventilation Inhalation of exhaust fumes and dust particles may be hazardous to ones health. Running engines welding, sanding, painting, and polishing tasks should be only done in well ventilated areas. Safe / Adequate Work Area The service area should be clean, spacious, level and free from holes in the floor, to prevent “slip”...
Page 6 (2) WORK – WEAR (GARMENTS Safe Work Clothing Appropriate safety wear (gloves, special shoes/boots, eye/ear protection, head gear, harness’, clothing, etc.) should be used/worn to match the task at hand. Avoid wearing jewelry, unbuttoned cuffs, ties or loose fitting clothes around moving machinery. A serious accident may occur if caught in moving/rotating machinery.
Page 7 (5) FASTENER TORQUE Torqueing Fasteners Always follow the torque values and procedures as designated in the service manual. Incorrect values, procedures and or tools may cause damage to the engine and or personal injury. (6) Electrical Short Circuits Always disconnect the (-) Negative battery cable before working on the electrical system.
Page 8 (8) FURTHER PRECAUTIONS Fueling / Refueling Keep sparks, open flames or any other form of ignition (match, cigarette, etc.) away when fueling/refueling the unit. Fire and or an explosion may result. Hot Surfaces. Do NOT touch the engine (or any of its components) during running or shortly after shutting it down.
Page 9 Precautions for Service Work (1) Precautions for Safety Read the safety precautions given at the beginning of this manual carefully and always mind safety in work. (2) Preparation for Service Work Preparation is necessary for accurate, efficient service work. Check the customer ledger file for the history of the engine.
Page 10 (2) How to Read the Explanations An exploded view, sectional views, a system diagram, etc. are shown at the beginning of each section as required for easy understanding of the mounted states of the components. For the removal/installation of each part, the procedure is shown with the procedural step No. in the illustration.
Page 11 Contents omitted in this manual Though the following jobs are omitted in the explanation in this manual, they should be conducted in actual work: Jacking up and lifting Cleaning and washing of removed parts as required Visual inspection (3) Definition of Terms [NOTICE]: Instruction whose negligence is very likely to cause an accident.
Page 12: Table Of Contents
CONTENTS 1. General ....................... 1 1.1 Engine Nomenclature ......................1 1.2 Specifications........................... 1 1.3 Fuel Oil, Lubricating Oil and Cooling Water................14 1.3.1 Fuel oil............................14 1.3.2 Lubricating oil .........................15 1.3.3 Cooling water .........................15 1.4 Engine External Views......................16 Structural Description ......................17 1.6 Exhaust gas emission regulation...................
Page 13 4. Disassembly, Inspection and Reassembly of Engines......59 4.1 Complete disassembly and reassembly ................59 4.1.1 Introduction ..........................59 4.1.2 Special service tools.......................60 4.1.3 Complete disassembly ......................65 4.1.4 Precautions before and during reassembly ................69 4.1.5 Adjusting operation.........................69 4.2 Cylinder Head: Disassembly, Inspection and Reassembly............ 70 4.2.1 Components (2-valve cylinder head)..................70 4.2.2 Disassembly procedure:......................70 4.2.3 Reassembly procedure: ......................71...
Page 14 5. LUBRICATION SYSTEM ................ 108 5.1 Lubrication System Diagram ....................108 5.2 Trochoid Pump Components ....................109 5.3 Disassembly(Reverse the procedure below for assembly) ..........109 5.4 Servicing Points........................109 5.5 Parts Inspection and Measurement..................110 5.5.1 Trochoid pump inspection and measurement............... 110 6.
Page 15 8.5 Washing and Inspection procedure ..................130 8.5.1 Washing ..........................130 8.5.2 Inspection procedure......................131 8.6 Reassembly Procedure ....................... 134 8.6.1 Preparation for reassembly....................134 8.6.2 Reassembly .........................134 8.7 Handling after Disassembly and Reassembly ..............137 8.7.1 Instructions for turbocharger installation................137 8.8 Troubleshooting ........................138 8.8.1 Excessively exhaust smoke ....................138 8.8.2 White smoke generation.......................138 8.8.3 Sudden oil decrease......................139...
Page 16 10. ALTERNATOR..................176 10.1 The 40A Alternator for 3TNV84 and other models............. 176 10.1.1 Components ........................176 10.1.2 Specifications ........................177 10.1.3 Wiring diagram ........................177 10.1.4 Standard output characteristics ..................178 10.1.5 Inspection ...........................178 10.2 Troubleshooting ......................... 179 11. ELECTRIC WIRING ................180 11.1 Electric Wiring Diagram .....................
Page 17: General
1. General 1. General 1.1 Engine Nomenclature The engine specification class Classification Load Engine speed Available engine speed (min Constant load Constant speed 1500/1800 Variable load Variable speed 2000-3000 The engine specification class (CL or VM) is described in the specifications table. 1.2 Specifications NOTE: 1) The information described in the engine specifications tables (the next page and after) is for...
Page 18 1. General (1) 3TNV82A Engine name Unit 3TNV82A Engine specification class Type Vertical, in-line, 4-cycle, water-cooled diesel engine Combustion chamber Direct injection Number of cylinders Cylinder bore stroke mm mm 82 84 Displacement 1.331 Revolving 1500 1800 Continuous speed rating 12.0 Output (hp)
Page 19 1. General (2) 3TNV84 Engine name Unit 3TNV84 Engine specification class Type Vertical, in-line, 4-cycle, water-cooled diesel engine Combustion chamber Direct injection Number of cylinders Cylinder bore stroke mm mm 84 90 Displacement 1.496 Revolving 1500 1800 Continuous speed rating 11.3 13.5 Output...
Page 20 1. General (3) 3TNV84T Engine name Unit 3TNV84T Engine specification class Type Vertical, in-line, 4-cycle, water-cooled diesel engine Combustion chamber Direct injection Number of cylinders Cylinder bore stroke mm mm 84 90 Displacement 1.496 Revolving 1500 1800 Continuous speed rating 14.0 16.5 Output...
Page 21 1. General (4) 3TNV88 Engine name Unit 3TNV88 Engine specification class Type Vertical, in-line, 4-cycle, water-cooled diesel engine Combustion chamber Direct injection Number of cylinders Cylinder bore stroke 88 90 Displacement 1.642 Revolving 1500 1800 Continuous speed rating 12.3 14.8 Output (hp) (16.7)
Page 22 1. General (5) 4TNV84 Engine name Unit 4TNV84 Engine specification class Type Vertical, in-line, 4-cycle, water-cooled diesel engine Combustion chamber Direct injection Number of cylinders Cylinder bore stroke 84 90 Displacement 1.995 Revolving 1500 1800 Continuous speed Rating 14.9 17.7 Output (hp) (20.3)
Page 23 1. General (6) 4TNV84T Engine name Unit 4TNV84T Engine specification class Type Vertical, in-line, 4-cycle, water-cooled diesel engine Combustion chamber Direct injection Number of cylinders Cylinder bore stroke mm mm 84 90 Displacement 1.995 Revolving 1500 1800 Continuous speed rating 19.1 24.3 Output...
Page 24 1. General (7) 4TNV88 Engine name Unit 4TNV88 Engine specification class Type Vertical, in-line, 4-cycle, water-cooled diesel engine Combustion chamber Direct injection Number of cylinders Cylinder bore stroke mm mm 88 90 Displacement 2.190 Revolving 1500 1800 Continuous speed rating 16.4 19.6 Output...
Page 25 1. General (8) 4TNV94L Engine name Unit 4TNV94L Engine specification class Type Vertical, in-line, 4-cycle, water-cooled diesel engine Combustion chamber Direct injection Number of cylinders Cylinder bore stroke mm mm 94 110 Displacement 3.053 Revolving 1500 1800 Continuous speed rating 26.1 31.3 Output...
Page 26 1. General (9) 4TNV98 Engine name Unit 4TNV98 Engine specification class Type Vertical, in-line, 4-cycle, water-cooled diesel engine Combustion chamber Direct injection Number of cylinders Cylinder bore stroke mm mm 98 110 Displacement 3.318 Revolving 1500 1800 Continuous speed rating 30.9 36.8 Output...
Page 27 1. General (10) 4TNV98T Engine name Unit 4TNV98T Engine specification class Type Vertical, in-line, 4-cycle, water-cooled diesel engine Combustion chamber Direct injection Number of cylinders Cylinder bore stroke mm mm 88 110 Displacement 3.318 Revolving 1500 1800 Continuous speed rating 37.9 45.6 Output...
Page 28 1. General (11) 4TNV106 Engine name Unit 4TNV106 Engine specification class Type Vertical, in-line, 4-cycle, water-cooled diesel engine Combustion chamber Direct injection Number of cylinders Cylinder bore stroke mm mm 106 125 Displacement 4.412 Revolving 1500 1800 Continuous speed rating 41.2 49.3 Output...
Page 29 1. General (12) 4TNV106T Engine name Unit 4TNV106T Engine specification class Type Vertical, in-line, 4-cycle, water-cooled diesel engine Combustion chamber Direct injection Number of cylinders Cylinder bore stroke mm mm 106 125 Displacement 4.412 Revolving 1500 1800 Continuous speed rating 51.5 61.8 Output...
Page 30: Fuel Oil, Lubricating Oil And Cooling Water
1. General 1.3 Fuel Oil, Lubricating Oil and Coolant Water 1.3.1 Fuel oil IMPORTANT: Only use the recommended fuel to obtain the best engine performance and prevent damage of parts, also prevent air pollution. (1) Selection of fuel oil Use the following diesel fuels for best engine performance: BS 2869 A1 or A2 Fuels equivalent to Japanese Industrial Standard, JIS.
Page 31: Lubricating Oil
1. General 1.3.2 Lubricating oil IMPORTANT: Use of other than the specified engine oil may cause inner parts seizure or early wear, leading to shorten the engine service life. (1) Selection of engine lube oil Use the following engine oil API classification CD or CF (Standards of America Petroleum Institute)
Page 32: Engine External Views
1. General 1.4 Engine External Views...
Page 33: Structural Description
1. General 1.5 Structural Description...
Page 34: Exhaust Gas Emission Regulation
1. General 1.6 Exhaust gas emission regulation The engines in this manual have been certified by the US EPA, California ARB and/or the 97/68/EC Directive. California Proposition 65 Warning Diesel engine exhaust and some of its constitutions are known to the State of California to cause cancer, birth defects, and other reproductive harm.
Page 35: Engine Identification
1. General 1.6.2 Engine identification (1) Emission control labels of US EPA EPA label for constant speed engines EPA label for variable speed engines (2) Emission control label for both EPA and ARB (3) 97/68EC Directive label...
Page 36: Guarantee Conditions For The Epa Emission Standard
1. General 1.6.3 Guarantee Conditions for the EPA Emission Standard The following guarantee conditions are set down in the operation manual. In addition to making sure that these conditions are met, check for any deterioration that may occur before the required periodic maintenance times.
Page 37 1. General (4) Perform maintenance without fail. Note: Inspections to be carried out by the user and by the maker are divided and set down in the “List of Periodic Inspections” and should be checked carefully. (5) Maintenance period and Quality guarantee period for exhaust emission related parts The maintenance of the parts related to the exhaust emission must be carried out in the maintenance period as shown in the below table.
Page 38: Inspection And Adjustment
2. Inspection and Adjustment 2. Inspection and Adjustment 2.1 Periodic Maintenance Schedule The engine periodic inspection timing is hard to determine as it varies with the application, load status, qualities of the fuel and lubricating oils used and handling status. General rules are described here. : User-maintenance : Parts replacement : Shop-inspection...
Page 39: Periodic Inspection And Maintenance Procedure
2. Inspection and Adjustment 2.2 Periodic Inspection and Maintenance Procedure 2.2.1 Check before Daily Operation Be sure to check the following points before starting an engine every day. Inspection Item Visual check around engine Fuel tank level check and fuel supply Lube oil level check and replenishment Coolant water level check and replenishment Fuel pipe and coolant water pipe inspection and maintenance...
Page 40 2. Inspection and Adjustment (Unit: liter) Model Total volume Effective volume (L) 3TNV82A 3TNV84(T) 88 4TNV84(T) 88 4TNV94L 98(T) 10.5 4TNV106(T) (CL class) 14.0 4TNV106(T) (VM class) 14.0 Lube oil capacity may differ from the above volume depending on an engine installed on a machine unit. (b) Replenishing oil pan with lube oil If the remaining engine oil level is low, fill the oil pan with the specified engine oil to the specified level through the filler port.
Page 41: Inspection After Initial 50 Hours Operation
2. Inspection and Adjustment IMPORTANT: If the coolant water runs short quickly or when the radiator runs short of water with the Coolant recovery tank level unchanged, water may be leaking or the air tightness may be lost. Increase in the Coolant recovery tank water level during operation is not abnormal.
Page 42 2. Inspection and Adjustment In early period of use, the engine oil gets dirty rapidly because of the initial wear of internal parts. Replace he engine oil earlier. Lube oil filter should also be replaced when the engine oil is replaced. The procedure of lube oil and lube oil filter replacement is as follows.
Page 43 2. Inspection and Adjustment (2) V-belt tension check When there is not enough tension in the V-belt, the V-belt will slip making it impossible for the alternator to generate power and cooling water pump and cooling an will not work causing the engine to overheat. Check and adjust the V-belt tension (deflection) in the following manner.
Page 44: Inspection Every 50 Hours
2. Inspection and Adjustment 2.2.3 Inspection every 50 hours Be sure to check the following points every 50 hours operation. Inspection Item Fuel tank draining Water separator draining Bleeding the fuel system Battery electrolyte level check and battery recharging (1) Fuel tank draining 1) Prepare a waste oil container.
Page 45 2. Inspection and Adjustment (3) Bleeding the fuel system Bleed the fuel system according to the following procedures. When there is air in the fuel system, the fuel injection pump will not be able to function. 1) Check the fuel oil level in the fuel tank. Refuel if insufficient.
Page 46 2. Inspection and Adjustment Battery structure (1) Electrolyte level Check the level of fluid in the battery. When the amount of fluid nears the lower limit, fill with battery fluid (available in the market) to the upper limit. If operation continues with insufficient battery fluid, the battery life is shortened, and the battery may overheat and explode.
Page 47 2. Inspection and Adjustment (b) Measurement with hydrometer When using a hydrometer, the measured specific gravity must be corrected according to the temperature at the time of measurement. The specific gravity of battery electrolyte is defined with 20 as the standard. Since the specific gravity increases or decreases by 0.0007 when the temperature varies by 1 , correct the value according to the equation...
Page 48: Inspection Every 250 Hours Or 3 Months
2. Inspection and Adjustment 2.2.4 Inspection every 250 hours or 3 months Be sure to check the following points every 250 hours or 3 months operation, whichever comes first. Inspection Item Lube oil and filter replacement Radiator fin cleaning V-belt tension check Inspection and adjustment of governor lever and accelerator Air cleaner cleaning and element replacement (1) Lube oil and filter replacement (The second replacement and after)
Page 49 2. Inspection and Adjustment (4) Inspection and adjustment of governor lever and accelerator The governor lever and accelerating devices (accelerating lever, pedal, etc.) of the machine unit are connected by an accelerating wire or rod. If the wire becomes stretched or the connections loose, the deviation in the position may result and make operation unsafe.
Page 50 2. Inspection and Adjustment 3) Blow air [0.29 0.49MPa (3.0 5.0kgf/cm )] from inside the element to blow dust off as shown in the illustration right. Apply the air blowing pressure as low as possible so as not to damage the element. If having the air cleaner with double elements, never remove and clean the inner element.
Page 51: Inspection Every 500 Hours Or 6 Months
2. Inspection and Adjustment 2.2.5 Inspection every 500 hours or 6 months Be sure to check the following points every 500 hours or 6 months operation, whichever comes first. Inspection Item Water separator cleaning Fuel filter element replacement Air cleaner cleaning and element replacement (1) Water separator cleaning Periodically wash the water separator element and inside cup with clean fuel oil.
Page 52 2. Inspection and Adjustment (2) Fuel filter element replacement Replace the fuel filter at specified intervals, before it is clogged with dust to adversely affect the fuel flow. Also, replace the fuel filter after the engine has fully been cooled. 1) Close the fuel cock of the water separator.
Page 53: Inspection Every 1,000 Hours Or One Year
2. Inspection and Adjustment 2.2.6 Inspection every 1,000 hours or one year Be sure to check the following points every 1,000 hours or one year operation, whichever comes first. Inspection Item Coolant water replacement Diaphragm assy inspection Turbocharger blower cleaning* Intake/exhaust valve clearance adjustment Fuel injection nozzle pressure inspection ( 1) Coolant water replacement...
Page 54 2. Inspection and Adjustment (2) Diaphragm assy inspection Inspect the diaphragm assy on the rocker arm cover every 1000 hours or 2 years. Refer to 4.2.4 point 6 for the function of the diaphragm. 1) Loosen screws, and remove a diaphragm assy, and check whether oil and so on doesn’t enter between the diaphragm and the cover.
Page 55 2. Inspection and Adjustment ( 3) Turbocharger blower cleaning* When engine speed seems sluggish or the exhaust color looks poor, the blades of the turbocharger-blower may be dirty. Wash the turbine blower in such a case. (a) General items 1) As for washing, use washing liquid and clear water. 2) Washing time is the time when about 10% of the boost pressure decreases more than that of usual operation state as a standard.
Page 56 2. Inspection and Adjustment (4) Intake/exhaust valve clearance adjustment Make measurement and adjustment while the engine is cold. (a) Valve clearance measurement 1) Remove the rocker arm cover above cylinder head. 2) Set the No.1 cylinder in the compression TDC Turn the crankshaft to bring the piston of the No.1 cylinder to its compression top dead center while watching the rocker arm motion, timing...
Page 57 2. Inspection and Adjustment The cylinder to be adjusted first does not have to be the No.1 cylinder. Select and adjust the cylinder where the piston is the nearest to the top dead center after turning, and make adjustment for other cylinders in the order of ignition by turning the crankshaft 240 each time.
Page 58 2. Inspection and Adjustment Push the bridge head so that a valve bridge and two valve stem heads may contact each other uniformly, and adjust an adjusting bolt so that a gap of the valve stem head may become 0. Tighten a locknut after a valve bridge is fixed with a wrench.
Page 59 2. Inspection and Adjustment (5) Fuel injection nozzle pressure inspection Wear protective glasses when testing injection from the fuel injection valve. Never approach the injection nozzle portion with a hand. The oil jetting out from the nozzle is at a high pressure to cause loss of sight or injury if coming into careless contact with it.
Page 60 2. Inspection and Adjustment [Informative: Fuel injection valve structure] (b) Spray pattern inspection After adjustment to the specified valve opening pressure, use a nozzle tester and check the spray pattern and seat oil-tightness. Seat oil tightness check After injecting a few times, increase the pressure gradually.
Page 61 2. Inspection and Adjustment Spray and injection states Operate the nozzle tester lever at a rate of once or twice a second and check no abnormal injection. If normal injection as shown below cannot be obtained, replace the fuel injection valve. No extreme difference in angle( ) No extreme injection angle difference( ) Finely atomized spray...
Page 62: Inspection Every 2000 Hours Or 2 Years
2. Inspection and Adjustment 2.2.7 Inspection every 2000 hours or 2 years Be sure to check the following points every 2,000 hours or two years operation, whichever comes first. Inspection Item Coolant water path flushing and maintenance Fuel pipe and coolant water pipe inspection and maintenance Intake/exhaust valve seat lapping Fuel injection timing adjustment Fuel injection pump inspection and adjustment...
Page 63 2. Inspection and Adjustment 1) Before removing a fuel pump drive gear, make ID marks on the gearing part of the pump drive gear and the idle gear with paint and so on. 2) Make the mark-off line to the gear case precisely in accordance with the position of mark-off line of the fuel pump.
Page 64 2. Inspection and Adjustment 7) Adjust the injection angle difference, calculated in the above 5), at 0.25 in the unit in the installation angle of the fuel pump while reading the mark (minimum 0.5 and cam angle) of the adjustment sticker. [NOTICE] Push down the fuel pump in the outside direction of the cylinder block at +1 degree when a injection...
Page 65: Adjusting The No-Load Maximum Or Minimum Speed
2. Inspection and Adjustment 2.3 Adjusting the no-load maximum or minimum speed 1) After warming the engine up, gradually raise the speed and set it at the no-load maximum revolution. 2) If the no-load maximum revolution is out of the standard, adjust it by turning the high idle limiting bolt.
Page 66: Sensor Inspection
2. Inspection and Adjustment 2.4 Sensor Inspection 2.4.1 Oil pressure switch Disconnect the connector from the oil pressure switch. Keep the voltammeter probes in contact with the switch terminal and cylinder block while operating the engine. It is abnormal if circuit is closed. 2.4.2 Thermo switch Place the thermo switch in a container filled with antifreeze or oil.
Page 67: Radiator Cap Inspection
2. Inspection and Adjustment 2.6 Radiator cap inspection Install the radiator cap on the cap tester. Set the tester pressure to 0.09 0.015MPa (0.9 0.15kgf/cm and see that the cap is opened. If the cap does not open, replace the cap since it is abnormal. 2.7 Thermostat Inspection Place the thermostat in a container filled with water.
Page 68: Adjusting Operation
2. Inspection and Adjustment 2.8 Adjusting Operation Perform the adjusting operation of a engine as follows after the maintenance job: 1) Supply the fuel oil, lubricating oil and coolant water. Note: Check the levels of the lubricating oil and coolant water again after test running (for about 5 minutes) and add as required.
Page 69: Troubleshooting
3. Troubleshooting 3. TROUBLESHOOTING 3.1 Preparation before troubleshooting If the signs of a trouble appear, it is important to lecture on the countermeasure and treatment before becoming a big accident not to shorten the engine life. When the signs of a trouble appear in the engine or a trouble occurs, grasp the trouble conditions fully by the next point and find out the cause of sincerity according to the troubleshooting.
Page 70: Quick Reference Table For Troubleshooting
3. Troubleshooting 3.2 Quick Reference Table for Troubleshooting The following table summarizes the general trouble symptoms and their causes. If any trouble symptom occurs, take corrective action before it becomes a serious problem so as not to shorten the engine service life. Poor Insufficient Cooling...
Page 71 3. Troubleshooting Poor Insufficient Cooling Starting failure exhaust Hunting Lubricating oil Trouble symptom engine output water intake color Engine starts Exhaust During but stops color work soon. Exhaust Corrective action smoke Cause Excessive cooling effect of radiator Defective thermostat (kept closed) (See 2.2.7 in Chapter2.) Defective thermostat (kept opened)(See 2.2.7 in Chapter2.) Insufficient cooling effect of radiator or slipping fan belt (See 2.2.2-2) in Chapter2.)
Page 72 3. Troubleshooting Poor Insufficient Cooling Starting failure exhaust Hunting Lubricating oil Trouble symptom engine output water intake color Engine starts Exhaust During but stops color work soon. Exhaust Corrective action smoke Cause Clogged air filter Clean. (See 2.2.4 in Chapter2.) Engine used at high temperatures or at high altitude Study output drop and load matching.
Page 73: Troubleshooting By Measuring Compression Pressure
3. Troubleshooting 3.3 Troubleshooting by measuring Compression Pressure Compression pressure drop is one of major causes of increasing blowby gas (lubricating oil contamination or increased lubricating oil consumption as a resultant phenomenon) or starting failure. The compression pressure is affected by the following factors: 1) Degree of clearance between piston and cylinder 2) Degree of clearance at intake/exhaust valve seat 3) Gas leak from nozzle gasket or cylinder head gasket...
Page 74 3. Troubleshooting (3) Engine speed and compression pressure (for reference) (4) Measured value and troubleshooting When the measured compression pressure is below the limit value, inspect each part by referring to the table below. Item Cause Corrective action Air cleaner element Clogged element Clean the element.
Page 75: Disassembly, Inspection And Reassembly Of Engines
4. Disassembly, Inspection and Reassembly of Engines 4. Disassembly, Inspection and Reassembly of Engines 4.1 Complete disassembly and reassembly 4.1.1 Introduction Make preparation as follows before starting engine inspection and service: 1) Fix the engine on a horizontal base. Be sure to fix the engine securely to prevent injury or damage to parts due to falling during the work. 2) Remove the coolant water hose, fuel oil pipe, wire harness, control wires etc.
Page 76: Special Service Tools
4. Disassembly, Inspection and Reassembly of Engines 4.1.2 Special service tools (1) Special Tools Tool name Applicable model and tool size Illustration Valve guide tool ㎜ (for extracting valve Model guide) 3TNV82A 4TNV94L 98(T) 4TNV106(T) 4TNV84 3TNV84(T) 3/4TNV88 4TNV84T ※Locally manufactured Valve guide tool ㎜...
Page 77 4. Disassembly, Inspection and Reassembly of Engines Tool name Applicable model and tool size Illustration Stem seal inserter (for inserting stem ㎜ seal) Model 3TNV82A 15.2 15.8 4TNV84 3TNV84(T) 16.2 13.5 18.8 4TNV88 4TNV84T 12.9 11.5 10.0 4TNE94L 98 15.2 11.8 4TNE106(T) 15.2...
Page 78 4. Disassembly, Inspection and Reassembly of Engines (2) Measuring instruments Instrument name Application Illustration Measurements of shaft bending, and strain and gap of surfaces Dial gage Measurements of narrow or deep portions that cannot be measured by dial gage Test indicator For holding the dial gage when measuring using a dial gage, standing angles adjustable...
Page 79 4. Disassembly, Inspection and Reassembly of Engines Instrument name Application Illustration For measuring shaft bend V-block For tightening nuts and bolts to the specified torque Torque wrench For measuring gaps between ring and ring groove, and shaft joints during assembly Thickness gage For checking water leakage Cap tester...
Page 80 4. Disassembly, Inspection and Reassembly of Engines Instrument name Application Illustration For measuring revolution by contacting the mortise in the revolving shaft Contact type Speedometer For measuring revolution by sensing the reflecting mark on the outer periphery of the revolving shaft Photoelectric type For measuring resistance, voltage and continuity of electrical circuits...
Page 81: Complete Disassembly
4. Disassembly, Inspection and Reassembly of Engines 4.1.3 Complete disassembly Peripheral parts such as air cleaner, muffler and radiator differ in installation and types for each application. Therefore, description in this Chapter is started with the steps to be taken just after the peripheral parts have been removed.
Page 82 4. Disassembly, Inspection and Reassembly of Engines Step Removal Parts Remarks 1) Disconnect coolant water pipe from the cooling water pump. 2) Remove thermostat assembly. 3) Remove cooling water pump. 1) Remove cylinder head tightening bolt. 1) Lay a cardboard or the like on the floor and 2) Remove cylinder head assembly.
Page 83 4. Disassembly, Inspection and Reassembly of Engines Step Removal Parts Remarks 1) Remove lubricating oil pump. 1) Remove starting motor from flywheel housing sing. 1) Remove flywheel mounting bolt. 1) Carefully protect the ring gear from damage 2) Remove flywheel. mage.
Page 84 4. Disassembly, Inspection and Reassembly of Engines Step Removal Parts Remarks 1) Remove main bearing cap bolt. While 1) Before extracting crankshaft, measure the shaking main bearing cap, remove main side gap around it. bearing cap together with lower main bearing metal.
Page 85: Precautions Before And During Reassembly
4. Disassembly, Inspection and Reassembly of Engines 4.1.4 Precautions before and during reassembly To reassemble engine components, reverse the procedure of disassembly. However, follow the precautions below and the precautions from in chapter 4 to in chapter 7 particularly before and during reassembly.
Page 86: Cylinder Head: Disassembly, Inspection And Reassembly
4. Disassembly, Inspection and Reassembly of Engines 4.2 Cylinder Head: Disassembly, Inspection and Reassembly 4.2.1 Components (2-valve cylinder head) 4.2.2 Disassembly procedure: Disassemble in the order of the numbers shown in the illustration. 1) Remove the alternator assy. (Point1) 2) Remove the fan, pulley and V belt. 3) Remove the thermostat case.
Page 87: Reassembly Procedure
4. Disassembly, Inspection and Reassembly of Engines 4.2.3 Reassembly procedure: Reverse order of the disassembly procedure.
Page 88: Servicing Points
4. Disassembly, Inspection and Reassembly of Engines 4.2.4 Servicing points Point1 [Disassemble] Loosen the mounting bolt while supporting the alternator. Do not tilt the alternator toward the cylinder block in haste since it may damage the alternator or pinch a finger.
Page 89 4. Disassembly, Inspection and Reassembly of Engines Point6 1) Removing pipe seals of 4 valve head. [Disassemble] Take off a rocker arm cover in case of 4 valve head after removing fuel injection pipes and pipe seals. [NOTICE] Attention is necessary because a fuel nozzle is caught in a pipe seal and the pipe seal is damaged when a rocker arm cover is lifted with a pipe seal sticking to the rocker arm cover.
Page 90 4. Disassembly, Inspection and Reassembly of Engines [NOTICE] 1) When a diaphragm is damaged, pressure control inside the crankcase becomes insufficient, and troubles occur. When the internal pressure of the crankcase decreases too much due to the damage of a spring, much blowby gas containing oil is reduced in intake air system, and it may cause the combustion defect by the early dirt of the intake valve or the urgent rotation of the engine by the oil burning.
Page 91 4. Disassembly, Inspection and Reassembly of Engines Point9 [Disassemble] Carefully remove the fuel injection valve so as not to leave the top end protector from being left inside the cylinder. [Reassemble] Replace the fuel injection valve protector with a new one. Point10 [Disassemble] When removing each intake/exhaust valve from...
Page 92: Parts Inspection And Measurement
4. Disassembly, Inspection and Reassembly of Engines 4.2.5 Parts Inspection and measurement (1) Cylinder head Clean the cylinder head, mainly the combustion surface, valve seats and intake/exhaust ports, remove carbon deposit and bonding agent, and check the surface state. (a) Appearance check Check mainly discoloration and crack.
Page 93 4. Disassembly, Inspection and Reassembly of Engines (2) Valve guide Mainly check damage and wear on the inside wall. Apply the service part code when replacing a part. Model Service part code Suction 124060-11800 3TNV82A (2-valve) Exhaust 119802-11810 4TNV84 Suction 120130-11860 3TNV84(T) 3/4TNV88...
Page 94 4. Disassembly, Inspection and Reassembly of Engines (3) Intake/exhaust valve Mainly clean and check damage and wear at the valve stem and seat. (a) Seat contact: See (1)-(d) above. (b) Stem outside diameter: See (2) above. (c) Valve head thickness Model Part Standard...
Page 95 4. Disassembly, Inspection and Reassembly of Engines (5) Valve rocker arm Mainly inspect valve head cap contact surface, inside surface defects and wear. Slight surface defects shall be corrected with an oilstone. Model Items Standard Limit Arm hole 16.00 16.02 16.07 diameter TNV82A 88...
Page 96: Valve Seat Correction
4. Disassembly, Inspection and Reassembly of Engines 4.2.6 Valve seat correction [NOTICE] Always check the oil clearance between the valve and valve guide before correcting the valve seat. If it exceeds the limit, replace the valve or valve guide first to make the clearance satisfy the standard. After correction, wash the valve and the cylinder head sufficiently with diesel oil to remove all grinding powder or compound.
Page 97: Valve Guide Replacement
4. Disassembly, Inspection and Reassembly of Engines 4.2.7 Valve guide replacement 1) Use a valve guide extraction tool(12.1-1 in Chapter 12) and extract the valve guide from the cylinder head. 2) Put liquid nitrogen or ether (or alcohol) with dry ice added in a container and put the valve guide for replacement in it for cooling.
Page 98: Valve Stem Seal Replacement
4. Disassembly, Inspection and Reassembly of Engines 4.2.8 Valve stem seal replacement Always use a new seal after the intake/exhaust valve is disassembled. Since the one for the exhaust valve is marked with yellow paint, do not confuse the intake and exhaust valves.
Page 99: Gear Train And Camshaft
4. Disassembly, Inspection and Reassembly of Engines 4.3 Gear Train and Camshaft 4.3.1 Components 4.3.2 Disassembly procedure: Disassemble in the order of the numbers in the illustration. 1) Perform steps 1) to 12) of the cylinder head disassembly procedure. 2) Remove the cooling water pump. 3) Remove the crankshaft pulley.
Page 100: Servicing Points
4. Disassembly, Inspection and Reassembly of Engines 4.3.4 Servicing points Point1 [Disassemble] Remove the crankshaft pulley using a gear puller after removing the crankshaft pulley set bolt. When removing the pulley using the gear puller, use a pad and carefully operate so as not to damage the thread.
Page 101 4. Disassembly, Inspection and Reassembly of Engines Point3: (Refer to 7.2.5 in chapter 7) [Disassemble] Remove the mounting nut of the fuel injection pump drive gear, remove the gear using the gear puller, and remove the fuel injection pump. Do not forget to remove the stay on the rear side.
Page 102 4. Disassembly, Inspection and Reassembly of Engines [Disassemble] Since the camshaft gear is shrink-fit, heat it to for extraction. For camshaft removal, raise the engine with its mounting flange at the bottom. After removing the thrust metal mounting bolt from the camshaft gear hole, extract the camshaft carefully so as not to damage the bearing bushing.
Page 103: Parts Inspection And Measurement
4. Disassembly, Inspection and Reassembly of Engines 4.3.5 Parts inspection and measurement (1) Camshaft Mainly check the contact between the tappet and cam contact surface, bearing seizure and wear, and gear damage. (a) Shaft bend measurement Support the camshaft with V blocks. Rotate the camshaft and measure the runout at the center of the camshaft and at each journal with a dial gage.
Page 104 4. Disassembly, Inspection and Reassembly of Engines Model Place Item Standard Limit Bushing I.D. 44.990 45.055 45.130 Gear side Camshaft O.D. 44.925 44.950 44.890 Oil clearance 0.040 0.130 0.240 Bushing I.D. 45.000 45.025 45.100 3TNV82A TNV88 Intermediate position Camshaft O.D. 44.910 44.935 44.875 Oil clearance...
Page 105: Oil Seal Replacement (Gear Case Side)
4. Disassembly, Inspection and Reassembly of Engines 4.3.6 Oil seal replacement (Gear case side) 1) Replace the oil seal with a new one when the gear case is disassembled. Extract the used oil seal. 2) Insert a new oil seal. Fit the position of the oil seal insertion to the end face of the gear case. (Refer to the below figure.) 3) Apply lithium grease to the oil seal tips.
Page 106: Cylinder Block
4. Disassembly, Inspection and Reassembly of Engines 4.4 Cylinder Block 4.4.1 Components 4.4.2 Disassembly procedure: Disassemble in the order of the numbers in the illustration. 1) Perform steps 1) to 12) in the cylinder head disassembly procedure. 2) Perform steps 1) to 12) in the gear train disassembly procedure. 3) Remove the oil pan.
Page 107: Servicing Points
4. Disassembly, Inspection and Reassembly of Engines 4.4.4 Servicing points Point1: Oil pan [Disassemble] Sealant is applied to the oil pan mounting surface on the block. Carefully operate soas not to damage or distort the bonding surface. [Reassemble] Apply sealant (code No.977770-01212) before reassembly.
Page 108 4. Disassembly, Inspection and Reassembly of Engines [Reassemble] Apply sealant (code No.977770-01212) and install the mounting flange by matching the two dowel pins. After assembly, raise the engine with its mounting flange on the bottom side. Unforeseen injury may arise due to falling of slipping when raising or reversing the engine.
Page 109 4. Disassembly, Inspection and Reassembly of Engines [Disassemble] Remove the bearing caps, cap side bearings, and thrust metals. Place each thrust metal with identification of the position and direction. The position number of reassembling is punched on a metal cap (except for both ends) and a cylinder block.
Page 110 4. Disassembly, Inspection and Reassembly of Engines Point6: Piston pin and rings [Disassemble] Using the piston ring replacer (see 4.1.2 in Chapter 4), remove the piston rings. Remove the circlip and remove the piston pin by pushing it out. [Reassemble] Install each piston ring on the piston, with the punched manufacturer’s mark facing upward.
Page 111: Parts Inspection And Measurement
4. Disassembly, Inspection and Reassembly of Engines 4.4.5 Parts inspection and measurement (1) Cylinder block Especially clean head surface, cylinder bores and oil holes, and check after removing any carbon deposit and bonding agent. (a) Appearance inspection Check if there is any discoloration or crack. If crack is suspected, perform color check.
Page 112 4. Disassembly, Inspection and Reassembly of Engines (c) If the limit is exceeded or any surface defect is found, repair by boring and honing. Use an oversized piston (and new piston rings) as required. Oversized piston (0.25 mm, with piston rings) Model Code No.
Page 113 4. Disassembly, Inspection and Reassembly of Engines (2) Crankshaft Mainly check seizure and wear of the crankpins and journals. Since the crankshaft gear is shrink-fitted, heat to 180 to 200 when extraction is necessary. (a) Shaft portion color check After washing the crankshaft, inspect it by means of color check or a magnaflux inspector.
Page 114 4. Disassembly, Inspection and Reassembly of Engines Crankpin Model & Item Standard Limit Pin outside diameter 42.952 42.962 42.902 3TNV82A Metal thickness 1.487 1.500 Oil clearance 0.038 0.090 0.150 Pin outside diameter 47.952 47.962 47.902 TNV84 88 Metal thickness 1.492 1.500 Oil clearance 0.038 0.074 0.150...
Page 115 4. Disassembly, Inspection and Reassembly of Engines Crank journal Model Item Standard Limit Journal O.D. 46.952 46.962 46.902 3TNV82A Metal thickness 1.987 2.000 Oil clearance 0.038 0.080 0.150 Journal O.D. 53.952 53.962 53.902 TNV84 88 Metal thickness 1.995 1.990 (Selective assembly) Oil clearance 0.038 0.068 0.150...
Page 116 4. Disassembly, Inspection and Reassembly of Engines Dimension R and finishing precision of crankshaft journal and pin As for grinding processing of journal and pin, machine it by using the grinding wheel of the dimension R of below table. Surface finishing precision standard on journal and pin: Ry=0.8S super polishing Surface finishing precision standard on the thrust...
Page 117 4. Disassembly, Inspection and Reassembly of Engines (4) Piston Especially clean the combustion surface, circumference, ring grooves and piston pin bosses, and check after removing any carbon deposit. Any burr at a ring groove or snap ring groove shall be removed.
Page 118 4. Disassembly, Inspection and Reassembly of Engines (c) Piston ring, ring groove and end clearance measurement Except for the top ring, to measure the piston ring groove width, first measure the width of the piston ring. Then insert the piston ring into the ring. Then insert the piston ring into the ring groove.
Page 119 4. Disassembly, Inspection and Reassembly of Engines Piston ring dimension Model Part Item Standard Limit Ring groove width 2.065 2.080 Ring width 1.970 1.990 1.950 Top ring Side clearance 0.075 0.110 End clearance 0.200 0.400 0.490 Ring groove width 2.035 2.050 2.150 Ring width 1.970 1.990...
Page 120 4. Disassembly, Inspection and Reassembly of Engines (5) Connecting rod (a) Appearance inspection Inspect the portion near the boundary of the chamfered portion and I-beam section of the big and small ends of the connecting rod as well as the portion near the oil hole of the bushing at the small end for cracks, deformation, and discoloration.
Page 121 4. Disassembly, Inspection and Reassembly of Engines (d) Rod big end measurement Measure the crankpin and bushing according to 4.4.5.(2)(c) described above. Calculate the oil clearance of a crank pin metal and a crank pin from the measured values of the crank pin metal inner diameter and the crank pin outside diameter.
Page 122: Cylinder Bore Correction
4. Disassembly, Inspection and Reassembly of Engines (6) Tappet Mainly check the tappet contact surface with the cam and push rod. Slight surface defects shall be corrected with an oilstone. (a) Tappet stem outside diameter measurement Model Item Standard Limit Tappet 12.000 12.025 12.045...
Page 123: Piston Pin Bushing Replacement
4. Disassembly, Inspection and Reassembly of Engines 3) Apply the honing fluid to the Flex-Hone and turn the electric drill at 300 to 1200 rpm. Then insert the Flex-Hone into the cylinder bore while turning it, and move it up and down for about 30 sec. to obtain a honing mark with a cross hatch angle of 30 to 40 .
Page 124: Lubrication System
5. Lubrication System 5. LUBRICATION SYSTEM 5.1 Lubrication System Diagram Note: It varies in the specifications of each model whether Oil cooler and Piston cooling of the * mark are attached.
Page 125: Trochoid Pump Components
5. Lubrication System 5.2 Trochoid Pump Components Trochoid pump (3TNV82A TNV88) Trochoid pump (4TNV94L/98/106) 5.3 Disassembly(Reverse the procedure below for assembly) 1) Loosen the belt, and remove the radiator pulley, fan and V-belt. See 4.2.2. 2) in Chapter 4. 2) Remove the crankshaft pulley. See 4.3.2. 3) in Chapter 4. 3) Remove the gear case cover.
Page 126: Parts Inspection And Measurement
5. Lubrication System 5.5 Parts Inspection and Measurement 5.5.1 Trochoid pump inspection and measurement (1) Outside clearance and side clearance of outer rotor Insert a gap gage between a outer rotor and a pump body, and measure the clearance. Outside clearance Model Standard Limit...
Page 127 5. Lubrication System (3) Rotor shaft clearance (4TNV94L/98/106) Measure the outside diameter of rotor shaft and the shaft hole diameter of gear case. Calculate the clearance from that difference. Model Inspection item Standard Limit Gear case bearing I.D. 12.980 13.020 13.05 4TNV94L/ 98 Rotor shaft O.D.
Page 128: Cooling System
6. Cooling System 6. COOLING SYSTEM 6.1 Cooling Water System 6.2 Cooling Water Pump Components...
Page 129: Disassembly (Reverse The Procedure Below For Assembly)
6. Cooling System 6.3 Disassembly (Reverse the procedure below for assembly) 1) Remove the alternator. See 4.2.2. 1) in Chapter 4. 2) Remove the fan, V-belt and pulley. See 4.2.2. 2) in Chapter 4. 3) Remove the cooling water pump. (Point 1, in below 6.4) 4) Remove the thermostat.
Page 130: Fuel Injection Pump/Governor
7. Fuel Injection Pump/Governor 7. FUEL INJECTION PUMP/GOVERNOR Only the outline of the MP fuel pump is explained in this chapter. Refer to the MP pump service manual of the separate volume for the disassembly and assembly. 7.1 Introduction It is described about the features of the fuel injection pump, YDP-MP, disassembly, assembly and adjustment procedure.
Page 131: External View And Components
7. Fuel Injection Pump/Governor 7.2.2 External view and components 7.2.3 Disassembly procedure: Disassembly from the engine body 1) Remove the cooling fan, pulley and V-belt. 2) Remove the fuel injection pipe, fuel oil piping, fuel return pipe and rear stay. See point 1 of 7.2.5. 3) Remove the fuel injection pump cover (the cover of the drive gear).
Page 132: Assembly Procedure
7. Fuel Injection Pump/Governor 7.2.4 Assembly procedure Reverse the disassembly procedure and adjust the fuel injection timing finally. See (4) of 2.2.7. 7.2.5 Servicing points Point 1 [Disassemble] Block an entrance with the tape so that trash may not enter the fuel injection pipe and the fuel injection pump.
Page 133 7. Fuel Injection Pump/Governor Point 3 [Disassemble] There is an acoustic material part to name as fuel pump spacer between the fuel pump and the cylinder block. Loosen fuel pump installation bolts with a closed wrench when disassembling a fuel pump.
Page 134: Turbochager: Disassembly, Inspection And Reassembly
8. Turbochager 8. TURBOCHAGER: Disassembly, inspection and reassembly 8.1 Structure and Functions 8.1.1 Main specifications 3TNV84T(CL, VM) Applicable engine model (application) 3TNV84T(VM) 4TNV106T(CL, VM) 4TNV84T(CL) Turbocharger model RHB31 RHB51 RHF5 Turbocharger specification Standard (w/waste gate) Turbine type Radial flow Blower (compressor) type Centrifugal Lubrication method External lubrication...
Page 135: Structural And Functional Outline
8. Turbochager 8.1.3 Structural and functional outline Part name Turbine shaft OiN thrower Turbine side seal ring Seal plate Journal bearing Thrust bearing Compressor housing M5 hexagon bolt M5 spring washer Compressor side clamp Turbine housing M6 hexagon bolt Turbine side clamp Lock washer Bearing housing Retaining ring...
Page 136: Components
8. Turbochager 8.1.4 Components Part name Part name Turbine shaft Bolt Thrust bushing Lock plate Oil thrower Bearing housing Seal ring Retaining ring Seal ring Screw Seal ring (turbine side) Screw Lock nut Lock washer Impeller Heat protector Seal plate Liquid gasket Journal bearing Waste gate actuator...
Page 137: Service Standards And Tightening Torque
8. Turbochager 8.2 Service Standards and Tightening Torque 8.2.1 Service standards (1) RHF5 type Unit: mm Standard dimension Wear limit Turbine shaft journal outside diameter (A) 7.99 8.00 7.98 Turbine shaft seal ring groove width (E) 1.25 1.28 1.29 Turbine Compressor side seal ring groove width (G1) 1.22 1.23 1.31...
Page 138: Tightening Torque
8. Turbochager (2) RHB31/RHB51 type Unit: mm Standard dimension Wear limit RHB31 RHB51 RHB31 RHB51 Turbine shaft journal outside diameter (A) 6.257 6.263 7.99 8.00 6.25 7.98 Turbine shaft seal ring groove width (E) 1.038 1.062 1.25 1.28 1.07 1.29 Turbine Compressor side seal ring groove width (G1) 1.02 1.03...
Page 139: Periodic Inspection Procedure
8. Turbochager 8.3 Periodic Inspection Procedure 8.3.1 Periodic inspection intervals Periodically inspect the turbocharger for the overall conditions and fouling. The inspection interval varies with the operating conditions, but refer to the table below for the guideline for each application. Application Inspection interval Every 6 months...
Page 140: Inspection Procedure
8. Turbochager 8.3.2 Inspection procedure (1) Rotor rotation inspection Inspect the rotor rotation by listening to any abnormal sound generation during rotation. For inspection with a sound detecting bar, bring the tip end of the bar into strong contact with the turbocharger case and raise the engine speed gradually.
Page 141: Waste Gate Valve Adjustment Procedure
8. Turbochager 8.3.3 Waste gate valve adjustment procedure Rotor play in radial direction It is indispensable to adjust the waste gate valve opening pressure and lift after its overhaul or inner parts replacement. Negligence of this adjustment will adversely affect the engine performance. [NOTICE] If the adjustment is impossible, give up overhaul but replace the whole turbocharger assembly.
Page 142 8. Turbochager (b) Measuring instruments and devices Dial gage Capable of measuring 0 to 10 mm (A flat head type is recommendable.) Manometer Mercury column or electrical type (capable of measuring 0 to 1500 mmHg) Pressure regulating valve Allowing gradual adjustment in a range between 0 and 2 kgf/cm (0.196 Mpa) Pressure reducing valve Used for suppressing the air supply pressure at 5 kgf/cm...
Page 143: Disassembly Procedure
8. Turbochager 8.4 Disassembly Procedure 8.4.1 Preparation for disassembly In addition to the general tools, the following special tools are required for turbocharger disassembly and reassembly: Tool name Illustration For removing thrust bearing and thrust bushing Material: Copper or brass For removing floating bearing circlip Pliers For removing seal ring...
Page 144: Inspection Before Disassembly
8. Turbochager 8.4.2 Inspection before disassembly 1) Inspect the turbine wheel and compressor impeller for any undesirable contact and the rotor for smooth rotation. 2) Measure the rotor play as described in section 8.3(2.2). Rotor axial play Wear limit: mm Rotor radial play Wear limit: mm 8.4.3 Disassembly The mounting angles of the turbine housing, bearing housing and compressor housing are determined...
Page 145 8. Turbochager (7) Floating bearing removal 1) Use the stop ring pliers and remove circlip 16 from bearing housing 15. 2) Remove floating bearing 5 from bearing housing 15. (8) Seal ring removal 1) Remove turbine side seal ring 3 from turbine shaft 1. 2) Remove compressor side seal ring (small) and compressor side seal ring (large) from oil thrower...
Page 146: Washing And Inspection Procedure
8. Turbochager 8.5 Washing and Inspection procedure 8.5.1 Washing (1) Inspection before washing Visually inspect each part before washing to check trace of seizure, wear, foreign matter or carbon adhesion. Carefully inspect for identifying the cause of trouble especially when a fault has occurred. Major inspection items Check point Checking position...
Page 147: Inspection Procedure
8. Turbochager 8.5.2 Inspection procedure (1) Compressor housing 7 Inspect the compressor housing for any contact trace with the compressor impeller, surface defect, dent or crack at joint surface, and replace it if defective. (2) Turbine housing 11 Inspect any trace of contact with the turbine wheel, exfoliation due to degradation by oxidation of the cast surface, thermal deformation or crack.
Page 148 8. Turbochager (6) Thrust bushing, oil thrower 2 and thrust bearing 6 Inspect each part for wear, surface defect and discoloration. Replace with a new one if defective even within the wear limit. (a) Thrust bushing Measure the distance between grooves (K) of the thrust bushing, and replace with a new one if the wear limit is exceeded.
Page 149 8. Turbochager (8) Bearing housing 15 1) Inspect the housing for cast surface exfoliation due to oxidation and degradation, dent or crack. 2) Inspect circlip 16 for chipping or crack, and replace with a new one if defective. 3) Measure the (B) and (F) portions of the bearing housing shown in the figure below.
Page 150: Reassembly Procedure
8. Turbochager 8.6 Reassembly Procedure 8.6.1 Preparation for reassembly 1) Prepare general tools, special tools, liquid gasket (Three Bond No.1207) and Locktite No.242 before reassembling the turbocharger. 2) Always replace the following parts with new ones: Turbine side seal ring 1pc. Compressor side seal ring(large) 1pc.
Page 151 8. Turbochager (3) Thrust bearing installation 1) Fit thrust bushing on turbine shaft 1. 2) Apply lubricating oil on the bearing portion of thrust bearing 6 and install it in bearing housing 3) Apply Locktite on the threaded portion of M3 Torx T machine screw 17 for thrust bearing installation, and use Torx torque driver for installation by tightening to the specified torque.
Page 152 8. Turbochager (5) Compressor impeller installation 1) Fit compressor impeller 18 onto turbine shaft 1. 2) Set a box spanner (10 mm) on the turbine side end of turbine shaft 1, and tighten shaft end nut Note: Since the shaft end nut has left-handed screw, pay attention to the tightening direction.
Page 153: Handling After Disassembly And Reassembly
8. Turbochager 8.7 Handling after Disassembly and Reassembly When installing the turbocharger on the engine or handling the turbocharger after installation, strictly observe the instructions given below. Especially pay careful attention for preventing foreign matter entrance into the turbocharger. 8.7.1 Instructions for turbocharger installation Lubrication system 1) Pour new lubricating oil through the oil filler port before installation on the engine, and manually turn the turbine shaft to lubricate the floating and thrust bearings.
Page 154: Troubleshooting
8. Turbochager 8.8 Troubleshooting Sufficient turbocharger performance and required engine output cannot be obtained if there is any fault. In such a case, first check each engine part to see there is no engine fault. Then inspect the turbocharger for troubleshooting according to the procedure shown below. 8.8.1 Excessively exhaust smoke (1) Insufficient intake air volume Cause...
Page 155: Sudden Oil Decrease
8. Turbochager 8.8.3 Sudden oil decrease Cause Corrective action 1) Excessive bearing wear causing abnormal wear or Turbocharger disassembly and repair damage of seal ring 8.8.4 Decrease in output Cause Corrective action 1) Gas leak from any part in exhaust piping Inspection and repair of defective portion 2) Air leak from discharge side of blower 3) Clogged air cleaner element...
Page 156: Starting Motor
9. Starting Motor 9. STARTING MOTOR As a representative example of starter, the one for 4TNV94L 98 and 4TNV106 (T) is shown in this chapter. 9.1 For 4TNV94L/ 98 9.1.1 Specifications Manufacturer’s model (Hitachi) S13-204 S13-205 Code 129900-77010 129900-77020 Nominal output Weight Revolution direction (as viewed from pinion) Clockwise...
Page 157: Components
9. Starting Motor 9.1.2 Components...
Page 158: Troubleshooting
9. Starting Motor 9.1.3 Troubleshooting...
Page 159: Names Of Parts And Disassembly Procedure
9. Starting Motor 9.1.4 Names of parts and disassembly procedure (1) Disassembling order 1) Nut M8 (Disconnect the connecting wire.) See the disassembly drawing. 2) Screw M4 (2) 3) Through bolt M5 (2) 4) Rear cover 5) Brush holder 6) Yoke assy. 7) Armature 8) Bolt M6 (2) 9) Magnetic switch...
Page 160 9. Starting Motor (2) Disassembly procedure 1) Nut M8 Remove the magnetic switch nut M8 (12 mm), and disconnect the connecting wire. 2) Screw M4 (2) 3) Through bolt M5 (2) 4) Rear cover Remove the M4 screw fastening the brush holder and remove through bolt M5 for rear cover removal.
Page 161 9. Starting Motor 6) Yoke Assy. 7) Armature Remove the brush holder. The armature and yoke assy can now be removed. 8) Bolt M6 (2) 9) Magnetic switch Remove bolt M6 (10 mm), and the magnetic switch can be removed. 10) Dust cover 11) Shift lever Take the dust cover out from the gear case.
Page 162 9. Starting Motor 12) Screw M4 (3) 13) Bearing retainer 14) Gear case Remove screw M4, and the bearing retainer and clutch assy can be removed. 15) Pinion stopper clip Remove the bearing retainer at the edge and the bearing, and shift the pinion stopper toward the pinion.
Page 163: Inspection And Maintenance
9. Starting Motor 9.1.5 Inspection and Maintenance (1) Armature (a) Commutator outside diameter Measure the commutator outside diameter and replace the commutator if the measured value is less than the limit. Standard Limit 36.5 35.5 (b) Armature coil continuity test Check continuity between commutator segments with a multimeter.
Page 164 9. Starting Motor (d) Armature and commutator run-out Use a dial gage and measure the armature core run-out and commutator run-out. Correct or replace if the limit is exceeded. Standard Limit Armature 0.03 Commutator 0.03 (e) Commutator surface inspection If the commutator surface is roughened, grind with #500 to #600 emery cloth.
Page 165 9. Starting Motor (2) Field coil (a) Field coil continuity test Check continuity between field coil terminals. Good if continuity exists. If no continuity (coil disconnection), replace the field coil. (b) Field coil insulation test Check continuity between field coil terminal and yoke. Good if no continuity exists.
Page 166 9. Starting Motor (4) Brush holder (a) Brush holder insulation test Check the continuity between the brush holder (+ side) and base (- side) with a multimeter. Good if no continuity exists. If continuity exists (insulation defect), replace the brush holder. (b) Brush spring inspection Inspect the brush spring pressure.
Page 167 9. Starting Motor (b) Series coil continuity test Check continuity between the S and M terminals. Good if continuity exists. If no continuity (coil disconnection), replace the magnetic switch. (c) Contact continuity test Depress the magnetic switch with the plunger at the bottom.
Page 168: Service Standards
9. Starting Motor (b) Pinion sliding inspection Check if the pinion slide smoothly in the axial direction. If damaged, rusted or heavy in sliding, repair it. If grease is applied too much on the pinion shaft, sliding becomes heavy. (c) Ball bearing inspection Rotate the ball bearing while holding the outer race with fingertips.
Page 169: Assembly
9. Starting Motor 9.1.7 Assembly The assembly procedure is the reverse of the disassembly procedure, but pay attention to the following points: (1) Grease application points Gears in the gear case Shift lever operating portion Pinion sliding portion Magnetic switch plunger sliding portion Use the specified grease as below table at all points.
Page 170 9. Starting Motor (3) Pinion projection length Connect the positive (+) lead from the battery to terminal S and negative (-) lead to terminal M. Turn the switch ON and measure the pinion moving distance L in the thrust direction. Perform this test within 10 seconds.
Page 171: Characteristic Test
9. Starting Motor 9.1.8 Characteristic test Since the characteristics can be checked roughly by means of a simple no-load test as explained elow. NOTE: Complete the test quickly since the rating of the starting motor is 30 seconds. (1) No-load test Fix the starting motor on a test bench and connect wiring as shown in Fig.31.
Page 172: For 4Tnv106(T)
9. Starting Motor 9.2 For 4TNV106(T) 9.2.1 Specifications Manufacturer’s model (Hitachi) S13-138 Code 129953-77010 Nominal voltage Nominal output Rating Revolution direction (as viewed from pinion) Clockwise Clutch system Roller clutch Engagement system Magnetic shift Pinion: Module/number of teeth M3/9 Weight Pinion projection voltage (at 100 ) 8 or less Terminal voltage/current...
Page 173: Troubleshooting
9. Starting Motor 9.2.3 Troubleshooting...
Page 174: Component Names And Disassembly Procedure
9. Starting Motor 9.2.4 Component names and disassembly procedure (1) Disassembly procedure 1) Disconnect the lead. 2) Remove the magnetic switch. 3) Remove the rear cover. 4) Remove the brush holder. 5) Disassemble the gear case and center bracket. 6) Remove the shift lever pin. 7) Remove the gear case dust cover.
Page 175: Disassembly Procedure
9. Starting Motor 9.2.5 Disassembly procedure (1) Disconnecting the lead Loosen the M8 nut (12mm) of the magnetic switch and disconnect the lead.
Page 176 9. Starting Motor (2) Removal of magnetic switch Remove the M6 bolts (10mm 2).
Page 177 9. Starting Motor (3) Removal of rear cover Remove the brush holder tightening screws (4mm 2) and the M5 through bolts ( 2). Next, disconnect the rear cover from the yoke using a – screwdriver.
Page 178 9. Starting Motor (4) Removal of brush holder For the negative (–) brush, bring the brush spring into contact with the side of the brush for lifting from the commutator surface. For the positive (+) brush, extract the pull out the brush from the brush holder. After the brush holder is removed, the armature and yoke can be disassembled.
Page 179 9. Starting Motor (5) Separating gear case from center bracket Remove three M6 bolts (10mm) fastening the gear case to the center bracket. After removal of the M6 bolts, the center bracket and oil seal can be removed.
Page 180 9. Starting Motor (6) Removal of shift lever pin Remove the M6 nut (10mm) and pull out the shift lever pin. Now. the dustcover, shift lever, gear case and gear shaft can be removed.
Page 181 9. Starting Motor (7) Removal of gear case dust cover Remove the two M5 bolts (using 4 mm hexagon wrench) to disassemble the dust cover from the gear case.
Page 182 9. Starting Motor (8) Removal of pinion Slide the pinion stopper towards the pinion and remove the pinion stopper clip using a – screwdriver.
Page 183: Inspection And Maintenance
9. Starting Motor 9.2.6 Inspection and maintenance (1) Armature 1) Check the commutator for rough surface. If so, smooth the surface using #500 to #600 emery cloth. If the outside periphery of the commutator has been deflected over 0.2 mm, repair by a lathe. 2) Measure the depth of the insulating material between commutator segments, and correct if it is less than 0.2 mm.
Page 184 9. Starting Motor 3) Armature coil continuity and earth tests Test type Measurement point Normal Abnormal (cause) Continuity test Across commutator None (open circuit) Earth test Between commutator and shaft or armature None Yes (short-circuiting) Replace if needed.
Page 185 9. Starting Motor (2) Field coil 1) Field coil continuity and earth tests Test type Measurement point Normal Abnormal (cause) Continuity test Across commutator None (open circuit) Earth test Between commutator and shaft or armature None Yes (short-circuiting) Replace if needed.
Page 186 9. Starting Motor (3) Brush 1) Check wear of the brush and the brush spring force.
Page 187 9. Starting Motor 2) Check of brush movement If the brush does not move smoothly, inspect the brush holder for bending and the brush holder sliding surface for dirt. Repair or clean as needed. 3) Check the continuity between the insulated brush holder (positive (+)) and the brush holder base (negative (-)).
Page 188 9. Starting Motor (4) Magnetic switch continuity test Test type Measurement point Normal Abnormal (cause) Shunt coil Between C and ground None (open circuit) Series coil C and M None Yes (short-circuiting) Replace if needed. S13-138 Resistance (at 20 ) Shunt coil Series coil 0.218...
Page 189: Assembly
9. Starting Motor (5) Pinion 1) Check the pinion teeth for wear and damage. Replace with a new one, if necessary. 2) Check if the pinion slides smoothly. If it is damaged or rusted or does not slide smoothly, repair. 3) Check springs for damage, and replace if necessary.
Page 190: Adjustment
9. Starting Motor 9.2.8 Adjustment (1) Pinion projection length L by magnetic switch Measure the pinion moving distance L (0.3 to 1.5mm) in the thrust direction when the pinion is protruded by the magnetic switch. If the distance L is outside the standard range, adjust by the dust cover as shown below.
Page 191: Service Standards
9. Starting Motor 9.2.9 Service standards Spring force N(kgf) 31.4 (3.2) Brush Standard / Limit height 18/6 Standard Outside diameter Limit Limit Commutator Deflection Correction accuracy 0.05 Limit Depth of insulation mica Correction accuracy 0.5 0.8 Front Armature shaft diameter Rear Gear shaft diameter 13.95 13.968...
Page 192: Alternator
10. Alternator 10. ALTERNATOR As a representative example of alternator, the alternator of 40A is shown in this chapter. 10.1 The 40A Alternator for 3TNV84 and other models 10.1.1 Components (1) Parts related to the alternator (2) Alternator components of the disassembly and assembly...
Page 193: Specifications
10. Alternator 10.1.2 Specifications Manufacturer’s model (Hitachi) ACFA68 Code 129423-77200 Rating Continuous Battery voltage Nominal output (13.5V heat) Rated revolution 5,000 Operating revolution 1,350 18,000 Grounding characteristics Minus side grounding Direction of revolution (viewed from pulley) Clockwise Integrated regulator IC regulator Weight Pulley (outside diameter) 69.2...
Page 194: Standard Output Characteristics
10. Alternator 10.1.4 Standard output characteristics The standard output characteristics of this alternator are shown as the right figure. 10.1.5 Inspection (1) V belt inspection 1) Inspect the matter whether there are not crack, stickiness and wear on the belt visually. Check that a belt doesn't touch the bottom part of the pulley groove.
Page 195: Troubleshooting
10. Alternator 10.1.6 Troubleshooting...
Page 196: Electric Wiring
11. Electric Wiring 11. ELECTRIC WIRING 11.1 Electric Wiring Diagram...
Page 197: Precaution On Electric Wiring
11. Electric Wiring 11.2 PRECAUTION ON ELECTRIC WIRING 11.2.1 Alternator In the cases listed below the warranty shall not be deemed to apply. Please be sure to read these conditions carefully when planning to use it with other equipment. Also be certain to give appropriate guidance on usage to the user.
Page 198: Starter
11. Electric Wiring 11.2.2 Starter In the cases listed below the warranty shall not be deemed to apply. Please be sure to read these conditions carefully when planning to use it with other equipment. Also be certain to give appropriate guidance on usage to the user.
Page 199: Current Limiter
11. Electric Wiring 11.2.3 Current limiter In the cases listed below the warranty shall not be deemed to apply. Please be sure to read these conditions carefully when planning to use it with other equipment. Also be certain to give appropriate guidance on usage to the user.
Page 200: Section Area And Resistance Of Electric Wire
11. Electric Wiring 11.2.4 Section area and resistance of electric wire (1) Allowable maximum cable length （Terminal resistance is not included.） Cable construction Note1 Ref. Note2 Cable size Resistance ( /m) Element No. Cable dia. 0.32 0.005590 0.36 3.58 8.94 0.32 0.003520 0.57...
Page 201: Service Standards
12. Service Standards 12. SERVICE STANDARDS 12.1 Engine Tuning Reference Inspection item Standard Limit page Gap at intake/exhaust valve heads TNV82A 98 0.15 0.25 2.2.6(4) mm 4TNV106(T) 0.25 0.35 Between alternator Used part 10 14 and crank pulley New part 8 12 V-belt tension Between alternator...
Page 202: Engine Body
12. Service Standards 12.2 Engine Body 12.2.1 Cylinder head (1) Cylinder head Inspection item Standard Limit Reference page Combustion surface distortion 0.05 or less 0.15 Intake 0.35 0.55 3TNV82A (2-valve head) Exhaust 0.30 0.50 TNV84 88 Intake 0.30 0.50 (2-valve head) 4.2.5.(1) Exhaust 0.30 0.50...
Page 203 12. Service Standards (2) Intake/exhaust valve and guide Reference Inspection item Standard Limit page Guide inside diameter 7.000 7.015 7.08 Intake Valve stem outside diameter 6.945 6.960 6.90 Clearance 0.040 0.070 0.18 3TNV82A (2-valve head) Guide inside diameter 7.000 7.015 7.08 Exhaust Valve stem outside diameter...
Page 204 12. Service Standards (3) Valve spring Reference Inspection item Standard Limit page 3TNV82A (2-valve) 44.4 43.9 4TNV84,3TNV84(T), 4TNV88 (2-valve) 42.0 41.5 Free length 4TNV84T (4-valve) 37.4 36.9 4TNV94L, 4TNV98(T), (4-valve) 39.7 39.2 4TNV106(T) (4-valve) 50.6 50.1 4.2.5.(4) 3TNV82A (2-valve) 4TNV84, 3TNV84(T), 4TNV88 (2-valve) Inclination 4TNV84T (4-valve) 4TNV94L, 4TNV98(T), (4-valve)
Page 205: Gear Train And Camshaft
12. Service Standards 12.2.2 Gear train and camshaft (1) Camshaft Reference Inspection item Standard Limit page Side gap 0.05 0.20 0.30 4.3.4 Bending (1/2 the dial gage reading) 0 0.02 0.05 3TNV82A-TNV88 38.600 38.800 38.350 4.3.5(1) Cam height 4TNV94L 98 43.400 43.600 43.150 4TNV106(T)
Page 206: Cylinder Block
12. Service Standards (2) Idle gear shaft and bushing Inspection item Standard Limit Reference page Shaft outside diameter 45.950 45.975 45.900 4.3.5(2) Bushing inside diameter 46.000 46.025 46.075 Clearance 0.025 0.075 0.175 (3) Backlash of each gear Reference Model Inspection item Standard Limit page...
Page 207 12. Service Standards (2) Crankshaft Reference Inspection item Standard Limit page Bending (1/2 the dial gauge reading) 0.02 Pin outside diameter 42.952 42.962 42.902 Metal inside diameter 43.000 43.042 3TNV82A Metal thickness 1.487 1.500 Clearance 0.038 0.090 0.150 Pin outside diameter 47.952 47.962 47.902 Metal inside diameter...
Page 208 12. Service Standards (3) Thrust bearing Inspection item Standard Limit Reference page Crankshaft side gap All models 0.13 0.23 0.28 4.4.4 (4) Piston and ring Piston Reference Inspection item Standard Limit page 3TNV82A 81.950 81.980 81.905 3,4TNV84(T) 83.945 83.975 83.900 Piston outside diameter 3,4TNV88 87.945 87.975...
Page 209 12. Service Standards Piston ring Reference Model Inspection item Standard limit page Ring groove width 2.065 2.080 Ring width 1.970 1.990 1.950 Top ring Side clearance 0.075 0.110 End clearance 0.200 0.400 0.490 Ring groove width 2.035 2.050 2.150 Ring width 1.970 1.990 1.950 3TNV82A...
Page 210 12. Service Standards (5) Connecting rod Inspection item Standard Limit Reference page Thrust clearance 0.2 0.4 4.4.4 Rod small end Reference Model Item Standard Limit page Bushing inside diameter 23.025 23.038 23.068 3TNV82A Pin outside diameter 22.995 23.000 22.967 Clearance 0.025 0.043 0.101 Bushing inside diameter...
Page 211: Lubricating Oil System (Trochoid Pump)
12. Service Standards 12.3 Lubricating Oil System (Trochoid Pump) (1) Outside clearance of outer rotor Model Standard Limit Reference page 3TNV82A 88 0.12 0.21 0.30 4TNV94L/98 0.100 0.155 0.25 5.5.1(1) 4TNV106(T) 0.100 0.165 0.25 (2) Side clearance of outer rotor Model Standard Limit...
Page 212: Tightening Torque For Bolts And Nuts
13. Tightening Torque for Bolts and Nuts 13. TIGHTENING TORQUE for BOLTS and NUTS 13.1 Tightening Torques for Main Bolts and Nuts Thread Lubricating oil diameter Tightening torque application Reference Part and engine model pitch (thread portion, page Nm(kgf m) and seat surface) 61.7 65.7 3TNV82A...
Page 213: Tightening Torques For Standard Bolts And Nuts
13. Tightening Torque for Bolts and Nuts 13.2 Tightening Torques for Standard Bolts and Nuts Nominal thread diameter Tightening torque Item Remarks pitch Nm(kgf-m) 9.8 11.8 Use 80% of the value at left M6 1 (1.0 1.2) when the tightening part is aluminum.
Page 214 SERVICE MANUAL FUEL INJECTION EQUIPMENT YPD-MP2/YPD-MP4 MODEL SERIES...
Page 215 Introduction This document describes the features, disassembly, reassembly and adjustment procedure of the fuel injection unit (Model YPD-MP2,MP4) for Diesel Engine Model TNV. Fuel injection unit is an essential mechanism of diesel engines, and thus, has to be designed to allow fine adjustment to the engine load.
Page 216 Contents ･･････････････････････････････････････････････････････････････････ FOR SAFE SERVICING 1.1. Warning Symbols ･････････････････････････････････････････････････････････････････････ 1.2. Safety Precautions ･･･････････････････････････････････････････････････････････････････････････････････････････････････････････････････････････････････ GENERAL INFORMATION 2.1. Outline of MP pump ･･････････････････････････････････････････････････････････････････ 2.2. Specifications ････････････････････････････････････････････････････････････････････････ 2.3. Outline of fuel injection pump ･･････････････････････････････････････････････････････････ 2.4. Construction of MP-Pump ･････････････････････････････････････････････････････････････ 2.4.1. Fuel Injection Part ････････････････････････････････････････････････････････････････...
Page 217 3.3.2. Re-assembling Cam Shaft ･････････････････････････････････････････････････････････ 3.3.3. Install the hydraulic head CMP. ･･････････････････････････････････････････････････ 3.3.4. Assembling the Hydraulic Head ･･･････････････････････････････････････････････････ 3.4. Re-assembling the Governor ･････････････････････････････････････････････････････････････････････････････････････････････････････････････････ 3.5. Combining Governor and Pump Bodies ･･････････････････････････････ ADJUSTMENT OF FUEL INJECTION PUMP AND GOVERNOR 4.1. Preparations ････････････････････････････････････････････････････････････････････････...
Page 218 6.2. Major faults and troubleshooting ･･････････････････････････････････････････････････････････････････････････････････････････ TIGHTENING TORQUES FOR MAIN BOLTS AND NUTS 7.1. Pump part ･･････････････････････････････････････････････････････････････････････････ 7.2. Mechanical governor part ････････････････････････････････････････････････････････････････････････････････････････････････････････････････････････････････････････････ TOOLS...
Page 219: For Safe Servicing
1. For Safe Servicing ! Most accidents are caused by negligence of basic safety rules and precautions. For accident prevention, it is important to avoid such causes before development to accidents. Please read this manual carefully before starting repair or maintenance to fully understand safety precautions and appropriate inspection and maintenance procedures.
Page 220: Safety Precautions
1.2. Safety Precautions ! Place allowing sufficient ventilation Jobs such as engine running part welding and polishing the paint with sandpaper should be done in a well-ventilated place． Failure to Observe Very dangerous for human body due to the possibility of inhaling poisonous gas or dust．...
Page 221 ! Wears for safe operation Wear a helmet，working clothes ，safety shoes and other safety protectors suited to the job. It is especially important to wear well-fiting work clothes. Failure to observe A serious accident such as trapping by a machine may occur. ! Use of appropriate tools Use tools appropriate for the jobs to be done.
Page 222: General Information
2. General information 2.1. Outline of MP pump MP pump is a fuel injection pump that has been newly developed to be installed on direct injection system diesel engines for the purpose of complying with the regulation for the exhaust gas emission that are becoming tighter in the future.
Page 223: Specifications
2.2. Specifications Model YPD-3MP2 YPD-4MP2 YPD-4MP4 4TNV94 Applicable Engine 3TNV82A /84(T)/88 4TNV84(T) /88 /98(T)/106(T) Plunger Diameter (mm) 10mm Max. Cam Lift (mm) 8.1mm 10mm Governor-System Mechanical All Speed Governor Fuel Injection Timing Control Built-in Hydraulic Control Timer System Fuel feed pump Forced Lubrication System With Trochoid Pump Lubrication system Engine System Oil...
Page 224: Outline Of Fuel Injection Pump
2.3. Outline of fuel injection pump Distribution type fuel injection pump YPD-MP consists of a hydraulic head that is equipped with a single plunger, a single distribution shaft, and delivery valves for each individual cylinders, a pump housing that includes camshafts, and a governor, all of which are integrated into the main unit of the pump.
Page 225: Construction Of Mp-Pump
2.4. Construction of MP-Pump 2.4.1. Fuel Injection Part Plug (C.W.) Plug (barrel) Joint (C.W.) Plug (distribution shaft) Holder (delivery) Thermo element. Delivery valve CMP. Holder (timer) Sleeve (distribution shaft) Piston (timer) Distribution shaft Hydrauric head Joint (distribution shaft) Packing (timer) Removal stop Barrel (plunger) (Transmission shaft)
Page 226: Governor Part
2.4.2. Governor Part 2.4.2.1. Construction of Governor Usage condition of diesel engines are extremely varied，with a wide range of loads and speeds．The governor plays an important role in the operation of the engine by quickly adjusting the position of the control rack to control the amount of fuel injected, according to changes of engine speed.
Page 227 As the spring lever and control lever are mounted on the same shaft, when the control lever is turned towards full, the governor spring is pulled and the load gradually increases. Since the tension lever can move freely around the governor shaft on the player bearing, as speed increases and the shifter is pushed to the left，the tension lever rotates clockwise, and when speed decreases，the tension lever rotates counterclockwise.
Page 228 (2) Engine stop device The magnetic solenoid is equipped to stop the engine. Injection volume Decrease Link Stop solenoid (3)Torque rise equipment As mentioned before，this governor has a structure that allows you to equip it with an anglich and/or torque spring as torque rise equipment.
Page 229 2.4.2.2. Function of Governor (1) Function of governor Following is a representation of the movement characteristics of the control rack at respective speeds，when the speed rise from 0,with the governor control lever at the maximum speed position: A-B : Fuel volume condition during starting. Volume is controlled by excess fuel spring. B-C : The rack moves towards decrease after engine starts and speed increase as the load of the excess fuel spring is overcome by the centrifugal force of the governor weight.
Page 230 (2) Starting control Moving the control lever to the max． speed position pulls the governor spring, and moves the tension lever until it comes in contact with the control stopper. When this is done，the excess fuel spring provided in between the tension lever and governor lever holds the control rack at the maximum starting injection volume position R After the engine is started, the excess fuel spring is compressed when the centrifugal force of the governor weight overcomes the set of the excess fuel spring as speed exceeds N...
Page 231 (4) Max speed The angle of the control lever is set at determined engine speed. The governor keeps engine speed constant by adjusting sped when load changes. For example, if the operator moves the control lever with the link from the idling position to max. Output, governor spring tension increases, the tension lever is pulled until it comes in contact with the full load stopper, the movement of the governor lever is transmitted...
Page 232 The angleich spring is mounted to the part of the tension lever (however some engine are not equipped with an angleich spring depending on usage and speed range utilized). When engine speed is low, the governor weight cannot compress the angleich spring as the angleich spring load is lager than the governor weight, thrust load, and the control rack is held at a position (R ) to increase...
Page 233 (6) Necessity of torque spring and function Engines used in construction machinery are subjected to sudden loads which cause a decrease in speed and sometimes results in stopping of the engine. A torque spring is provided to move the control rack towards injection volume increase when engine speed decrease，...
Page 234 (7) No load max. speed When the load decreases from full load max. speed and engine speed further increase, the increased thrust load of the governor weight acting on the governor spring through the tension lever exceeds the set load of the spring, the tension lever and governor lever descend clockwise, the control rack is pushed to the no load injection volume position (RH), and the engine is...
Page 235: Delivery Part
2.4.3. Delivery Part Delivery Ports and Cylinder Number 4MP2, 4MP4 １２３４ Cylinder No. Port No. Injection Order Driving side Flywheel side 3MP2 Cylinder No. Port No. Injection Order Driving side Flywheel side...
Page 236: Function Of Component
2.5. Function of Component 2.5.1. F.O. Feed Pump The FO feed pump feeds fuel oil from the fuel tank to the fuel injection pump via the water separator and fuel filter. The trochoid FO feed pump, installed on the fuel injection pump side, is driven by the fuel camshaft via the bevel gear. This feed pump can feed high pressure fuel oil into the FO injection pump, but while the fuel oil inside the piping is empty due to shortage of gases, etc., the pump’s self-feeding performance is low.
Page 237 2.5.1.1. Specifications of F.O. Feed Pump YPD-MP2 YPD-MP4 Suction Head （ｋPａ） Std. Delivery Pressure 0.4-0.5 0.6-0.7 （MPａ） Std. Delivery Volume /min）（cm Pressure & delivery volume figures at conditions below: Conditions: Outlet orifice dia. :φ0.7mm F.O. grade : ISO 8217 Revolutions : 1000min －１...
Page 238: Timer Mechanism
2.6. Timer Mechanism When the engine is used in a wide range from low to high speeds, it is necessary to change the fuel injection timing according to the engine speeds for always keeping the optimum firing timing. It is also necessary to optimize the injection timing for reducing noise and exhaust gas emissions.
Page 239: Cold Start Device)
2.7. C.S.D.(Cold Start Device) 2.7.1. Cold Starting Advancer Purpose In order to facilitate easy engine starting under cold temperatures, the advancer senses the cooling water temperature for advancing the fuel injection timing. 2.7.1.1. Structure & Function At cold starting At normal operating Termo-elementt Engine coolant Sub-port...
Page 240: Disassembly ,Reassembly And Inspection
3. Disassembly ,Reassembly and Inspection 3.1. Disassembly Disassembled parts must be put aside in order. Wash them before reassembly. 3.1.1. Separating the pump body from the governor body Rotating the link lifter will move the inside link upward/downward, so the control rack may be engaged/disengaged.
Page 241: Separating The Governor Weight Cmp
3.1.2. Separating the governor weight CMP Disassembling the delivery valve Remove the holder, (delivery). Providing whirl-stop to the camshaft Remove the delivery valve and gasket. Example of whirl-stop Remove the nut, (governor support). Delivery valve parts disassembled. (Take care not to mix these with other parts on reassembly.
Page 242 Remove the distribution shaft. Remove the holder and gasket, (timer) Removed parts must be stored in the cleaning oil sump. Remove the plug, (accumulator). Remove the plug and gasket, (barrel). Make sure that the seal washer remains on the plug. Remove the plug, (C.W.) and the joint, (C.W.) Parts disassembled.
Page 243: Separating Hydraulic Head Cmp
3.1.4. Separating hydraulic head CMP 3.1.5. Separating the cam shaft Remove the joint, (distribution shaft). Remove the hydraulic head CMP fixing bolt. Remove the feed pump. Do not loosen two bolts (A) Remove the hydraulic head CMP. O-ring Make sure that two O-rings are free from damages.
Page 244 Lift the transmission shaft slightly by your hand. Remove the whirl-stop, (tappet). Align the camshaft’s key groove with the embossed mark on the body. Take out the tappet. Tappet disassembled and FIC adjust shim. Lift the transmission shaft a little and pull out the camshaft. Remove the retainer, (bearing) fastening bolt.
Page 245: Disassembling The Hydraulic Head Cmp
Remove the transmission shaft CMP. 3.1.6. Disassembling the hydraulic head CMP Remove the rack guide. Remove the spring retainer. Compress the plunger spring and remove the spring retainer, (B). While compressing the plunger spring using special service tool, remove spring retainer B. Spring retainer B.
Page 246: Disassembling The Governor
3.2. Disassembling the Governor Removed governor lever shaft Remove the lock nut, (Control lever). Remove the regulator lever. Take out the governor lever CMP. Remove the shim. Remove the spring. Remove the removal stop, (governor lever shaft) fixing bolt. Remove the removal stop, (governor lever shaft). Pull out the governor lever shaft.
Page 247: Reassembly
3.3. Reassembly 3.3.1. Re-assembling the hydraulic head Install the rack guide. Rack guide Rack auxiliary SP Control sleeve Rack Install the plunger. Upper lead Upper spring retainer Sub-lead Distribution shaft sleeve Identification marking Ball Attaching rack and rack guide ! When installing rack guide, push it against the ! Note that the positional relationship of the upper distribution shaft sleeve and upper spring retainer so lead and sub-lead of the plunger and the ball of...
Page 248: Re-Assembling Cam Shaft
3.3.2. Re-assembling Cam Shaft Install the rack guide fastening bolt. Install the transmission shaft CMP. Tightening Torque : 3.9-4.9 N-m Spring retainer (B). Spring. Install the plunger spring and spring retainer (B). Attaching transmission shaft CMP ! Apply molybdenum disulfide to the shaft section. ! Check that the transmission shaft rotates Install the camshaft.
Page 249 Install the camshaft. Attaching camshaft Tightening Torque : 8-10 N-m ! Apply molybdenum disulfide to the bushing or the bearing. ! Insert the camshaft into the pump body with transmission shaft CMP at the lowered position (gear B touching the pump body). ! Be careful that the cam and gear B do not interfere with each other.
Page 250 Position the camshaft key groove as shown in the illustration. Engagement of gears ・ With the phase of camshaft and collar of transmission shaft set in the direction as shown below, engage gears A and B with each other. (Check that the match mark of gear B and the mark of gear A shown below are aligned with each other by looking through the feed pump installation hole.) ・...
Page 251 Whirl-stop groove Fasten the nut, (governor support), (and provide the whirl-stop to the cam shaft.) Tightening Torque : 79 - 84 N-m Install the tappet. Direct the tappet’s whirl-stop groove as shown in the illustration. Assembling tappets ! Insert tappet into the pump body with the slit directed toward the lock side, and attach the tappet lock.
Page 252: Install The Hydraulic Head Cmp
3.3.3. Install the hydraulic head CMP. Install the hydraulic head CMP. Insert the two positioning pins. Be sure not to confuse packing front with rear surface. (Align them with holes Installing H head on the body.) ! Assemble shims with an appropriate thickness that corresponds to the measurement of the bottom clearance (refer to attached drawing 3).
Page 253: Assembling The Hydraulic Head
Install the distribution shaft. Inserting distribution shaft ・ Insert distribution shaft so that the directional relationship between the shaft and camshaft is as shown below (Do not assemble upside down). Measure the plunger top position. ・ Use the following drawing simply as a reference because the component can be inserted in either of Bottle clearance adjustment should refer to Page 59.
Page 254 Install the new packing, (delivery valve seat). Install the plug, (distribution shaft). Fasten the plug, (distribution shaft). Install the delivery valve CMP. Tightening Torque : 10-15 N-m Holder(delivery Spring(delivery Valve(delivery Returnvalve （φ２） Spring seat(return valve Returnspring Seat(delivery Packing(delivery Install the plug with new copper packing, (barrel). Install the spring, (delivery).
Page 255 Install the new packing, (timer). Fasten the holder, (timer). Install the thermo-element with new O-ring. ! Before installing the thermo-element, press Install the holder with new O-ring, (timer). down the piston with the timer holder being installed to the head, (T=40-45N.m), and C.W.plug check that the piston returns up through the Thermo-element...
Page 256 F.O. valbe return pipe F.O. outlet Cooling water Fasten the thermo-element. F.O. inlet Tightening Torque : 30-35 N-m Install the joint, (FO inlet). nstall the joint, (C.W), and he plug, (C.W.) Assemble the seal washers, taking care not the washer stride over steps.
Page 257: Re-Assembling The Governor
3.4. Re-assembling the Governor Install the shim to the shaft, (control lever). Governor Body Parts Install the regulator lever. Governor Lever CMP End Float Adjust Shim Pierce the spring, (control lever) through the lock nut, (control lever) and fasten it to the thread of the shaft, (control lever). Pierce the governor lever CMP and shim through the governor lever shaft and assemble.
Page 258: Combining Governor And Pump Bodies
3.5. Combining Governor and Pump Bodies Turn the link lifter plate counterclockwise. and install the governor body to the pump bodies Install the new packing. Do not confuse front with rear surface. Assemble it, while aligning bolt holes with those on the body. Rack Link Link lifter...
Page 259 Install the governor case cover to the case. Insert the governor link into the link hole of the pump body. This completes reassembly of the pump. Fit the link lifter to the installation hole and fasten the bolt. Pull the governor assembly slightly to check that the link is engaging securely.
Page 260: Adjustment Of Fuel Injection Pump And Governor
4. Adjustment of Fuel Injection Pump and Governor Adjust the fuel injection pump after you have completed reassembly. The pump itself must be readjusted with a special pump tester when you have replaced major parts such as the plunger assembly, roller guide assembly, fuel camshaft, etc. Procure a pump tester like the one illustrated below.
Page 261 (4) Remove the plug in the oil fill hole on the top of the governor case, and fill the pump with about 200cc of pump oil or engine oil. (5) Complete fuel oil piping and operate the pump tester to purge the line of air. (6) Set the pressure of oil fed from pump tester to injection pump at 19.6-29.4kPa(0.2-0.3kgf/cm ) ,temp.
Page 262: Bottom Clearance Adjustment(Fuel Injection Timing)
4.2. Bottom clearance adjustment(Fuel Injection Timing) The Fuel Injection Timing of MP-pump is made by means of adjusting the bottom clearance of the Cam ie. adjustment of the Bottom clearance gauge Pre-stroke of the plunger , as follows. The adjustment of the clearance shall be made at cam-top position in order to get the reliable and easier method.
Page 263: The Bottom Clearance Adjusting Value And The Cam Classification
4.2.1. The bottom clearance adjusting value and the Cam classification Cam shaft Plunger bottom Standard shim Clearance (dimension: A) thickness (mm) Cam speed 3 cylinder 4 cylinder (mm) 1.1 m/s 158552-51020 158553-51020 25.5±0.05 1.3 m/s 158552-51030 158553-51030 25.9±0.05 1.7 m/s 158552-51040 158553-51040 26.3±0.05...
Page 264: Adjustment Of Governor
4.3. Adjustment of Governor 4.3.1. Adjustment of No Load Max. Engine Speed Set the engine speed at the no load max. speed. Pull the regulator lever and adjust the max. speed limit bolt to obtain the specified injection amount. Fasten the nut after completing the adjustment. 4.3.2.
Page 265: Adjustment Of Reverse Angleich
4.3.4. Adjustment of Reverse Angleich In the case of the governor with reverse angleich mechanism, use the reverse angleich spring in the assembled state. Adjustment of Reverse Angleich Make adjustment of reverse angleich after completing the following processes: Adjustment of fuel volume limiter bolt ●...
Page 266: Adjustment Of Staring Injection Amount
4.3.5. Adjustment of Staring Injection Amount ① Set the engine speed at the starting injection amount adjust speed and leave the regulator lever at the position in 2 above. ② Screw in the starting injection amount adjust bolt and adjust it to obtain the specified injection amount.
Page 267: Fuel Injection Nozzle
5. Fuel injection Nozzle When fuel 0il pumped by the fuel injection pump reaches the injection nozzle， it pushes up the nozzle valve （held down by spring），and is injected into the combustion chamber at high pressure． The fuel is atomized by the nozzle to mix uniformly with the air in the combustion chamber. How well the fuel is mixed with high temperature air directly affects combustion efficiency，engine Performance and fuel economy．...
Page 268: Fuel Injection Nozzle Disassembly
Nozzle body identification number The type of nozzle can be determined from the number inscribed on the outside of the nozzle body. 1）Hole type fuel injection nozzles 5.3. Fuel injection nozzle disassembly Note: 1. Disassemble fuel injection nozzle in a clean area as for fuel injection pump. 2.
Page 269: Fuel Injection Nozzle Inspection
（3）Remove the nozzle nut NOTE: Use a special box spanner for the hole type (the thickness of the two nozzle nuts is 15mm(0.5906in.)). (4) Remove the inner parts NOTE: Be careful not to loosen the spring seat, adjusting shims or other small parts. 5.4.
Page 270: Nozzle Inspection
5.4.2. Nozzle inspection （1）Inspect for scratches/wear lnspect oil seals for abnormal scratches or wear and replace nozzle if the nozzle sliding surface or seat are scratched or abnormally worn. (2）Check nozzIe sliding Wash the nozzle and nozzle body in clean diesel oil，and make sure that when the nozzle is pulled out about half way from the body，it slides down by itself when released.
Page 271: Fuel Injection Nozzle Reassembly
5.5. Fuel injection nozzle reassembly The fuel injection nozzle is reassembled in the opposite order to disassembly. (1) Insert the adjusting shims, nozzle spring and nozzle spring seat in the nozzIe holder，mount the stop plate with the pin i nsert the nozzle body/nozzle set and tighten the nut. (2) Use the special holder when tightening the nut for the hole type nozzle as in disassembly.
Page 272: Injection Test
5.6.2. Injection test After adjusting the nozzIe to the specified starting pressure, check the fuel spray condition and seat oil tightness. (1) Check seat oil tightness After two or three injections, gradually increase the pressure up to1.96MPa (20kg/cm ）before reading the starting pressure maintain the pressure for 5seconds, and make sure that no oil is dripping from the tip of the nozzle.
Page 273: Troubleshooting
6. Troubleshooting 6.1. Troubleshooting of fuel injection pump Complete repair means not only replacing defective parts, but finding and eliminating the cause of the trouble as well. The cause of the trouble may not necessarily be in the pump itself, but may be in the engine or the fuel system.
Page 274 Nozzle doesn't (1) Nozzle valve doesn't open or close normally. Repair or replace work. (2) Nozzle seat is defective. Repair or replace (3) Case nut is loose. Inspect and tighten (4) Injection nozzle starting pressure is too low. Adjust (5) Nozzle spring is broken. Replace (6) Fuel oil filter is clogged.
Page 275 4. Idling is rough. (1) Movement of central rack is defective. 1) Stiff plunger movement or sticking. Repair or replace 2) Rack and pinion fitting is defective. Repair 3) Movement of governor is improper. Repair 4) Delivery holder is too tight. Inspect and adjust (2) Uneven injection volume.
Page 276 7. Tightening torques for main bolts and nuts 7.1. Pump part Tightening torque ( N-m ） Tightening torque ( N-m ） Name of parts Name of parts 25 - 29 4 - 5 Pipe joint bolt, fuel inlet 18 Tappet guide M6×1（hexagon socket head）...
Page 277 7.2. Mechanical governor part Tightening torque ( N-m ） Tightening torque ( N-m ） No. Name of parts No. Name of parts 6 - 8 8 - 10 Fixing bolt, tension lever hook 10 Bolt, solenoid M6×1 M6×1 5 - 7 8 - 10 Fixing bolt, patch 11 Bolt, governor lever shaft...
Page 278 8. Tools Name of tool Shape and size application Nozzle plate 158090-51700 Bottom clearance gauge 158090-51800 : MP2 158090-51810 : MP4 Bottom clearance gauge Bottom clearance gauge Plunger SP seat extractor 158090-51900...
Page 279 M9961-03E070 Literature No . Revision history list Page No Document name SERVICE MANUAL FOR FUEL INJECTION EQUIPMENT Product name YDP-MP2 / YDP-MP4 Revision date Reason for Revision Revision item Revision No Revised by (A.D.) revision outline (page)

Komatsu 3D82AE Series Shop Manual

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