User Manuals: Yanmar D30G Diesel Forklift Truck

Manuals and User Guides for Yanmar D30G Diesel Forklift Truck. We have 1 Yanmar D30G Diesel Forklift Truck manual available for free PDF download: Service Manual

Yanmar D30G Service Manual

Yanmar D30G Service Manual (246 pages)

(4TNV98 : EM0Q3, EM0Q4, EM0Q5); (4TNE98 : EM0QC, EM0QD, EM0QE)

Brand: Yanmar | Category: Engine | Size: 9 MB

Table of Contents

Section 1. General Service Section 2. Periodic Maintenance Information

5
- Important Safety Information
  3
- Table of Contents
  5
- Component Identification
  9
- Emission Control Regulations
  10
  - Epa / Arb Regulations - Usa Only
    10
- Location of Labels
  10
  - Engine Nameplate (Typical)
    10
- Emission Control Labels
  11
- Engine Family
  11
- Function of Major Engine Components
  12
- Function of Cooling System Components
  13
- Diesel Fuel
  14
  - Diesel Fuel Specifications
    14
  - Filling the Fuel Tank
    15
  - Priming the Fuel System
    17
- Engine Oil
  18
  - Engine Oil Specifications
    18
  - Engine Oil Viscosity
    18
  - Checking Engine Oil
    19
  - Adding Engine Oil
    19
  - Engine Oil Capacity (Typical)
    19
- Engine Coolant
  20
- Principal Engine Specifications
  24
  - Tnv98 Epa Tier
    24
  - TNE98 EPA Tier 3
    25
- Engine Service Standards
  26
- Tightening Torques for Standard Bolts and Nuts
  27
- Abbreviations and Symbols
  29
- Unit Conversions
  30
  - Units of Torque
    30
  - Unit Prefixes
    30
  - Units of Length
    30
  - Units of Pressure
    30
  - Units of Volume
    30
  - Units of Power
    30
  - Units of Mass
    30
  - Units of Force
    30
  - Units of Temperature
    30
- Section 2. Periodic Maintenance
  31
  - Introduction
    42
  - Performing Periodic Maintenance
    42
  - Yanmar Replacement Parts
    42
  - Periodic Maintenance Schedule
    43
  - Periodic Maintenance Procedures
    45
  - Daily
    47
    
    After Initial 50 Hours of Operation
    47
    
    Every 50 Hours of Operation
    50
    
    Every 250 Hours of Operation
    53
    
    Every 500 Hours of Operation
    56
    
    Every 1000 Hours of Operation
    61
    
    Every 1500 Hours of Operation
    63
    
    Every 2000 Hours of Operation
    64
    
    Before You Begin Servicing
    65
    
    Introduction
    68
  - Cylinder Head Specifications
    68
    
    Adjustment Specifications
    68
    
    Intake / Exhaust Valve and Guide Cont
    69
    
    Push Rod
    70
    
    Rocker Arm and Shaft
    70
    
    Valve Spring
    70
  - Camshaft and Timing Gear Train Specifications
    70
    
    Idler Gear Shaft and Bushing
    71
    
    Timing Gear Backlash
    71
  - Crankshaft and Piston Specifications
    72
    
    Thrust Bearing
    72
    
    Piston
    73
    
    Connecting Rod
    74
  - Cylinder Block Specifications
    75
    
    Special Torque Chart
    75
    
    Torque for Bolts and Nuts
    75
    
    Special Service Tools
    77
  - Measuring Instruments
    79
  - Cylinder Head
    82
    
    Cylinder Head Components
    82
    
    Disassembly of 4-Valve Cylinder Head
    84
    
    TNE98 Engine
    89
    
    Disassembly of Cylinder Head
    91
    
    Cleaning of Cylinder Head Components
    94
    
    Reassembly of Cylinder Head
    100
  - Measuring and Adjusting Valve Clearance
    106
  - TNE98 Engine
    107
  - TNV98 Engine
    108
  - Crankshaft and Camshaft Components
    111
    
    Disassembly of Camshaft and Timing
    113
    
    Disassembly of Engine
    113
Table of Contents

116
- Figure
  117
- Components
  118
- Disassembly of Crankshaft and Piston
  118
- Figure
  118
- Figure
  121
  - Components
    122
    
    Inspection of Crankshaft and Camshaft
    122
    
    Honing and Boring
    128
    
    Components
    129
    
    Reassembly of Crankshaft and Piston
    129
    
    Components
    138
    
    Reassembly of Camshaft and Timing
    138
    
    Final Reassembly of Engine
    140
  - Before You Begin Servicing
    141
- Section 4. Fuel System
  141
  - Method B : Use a Feeler Gauge to Measure the
    121
  - See Thrust Bearing on Page 70 for the Service
    121
  - Tnv98 Engine
    143
  - Cold Start Device
    144
  - Stop Solenoid
    144
  - Trochoid Fuel Pump
    144
  - Fuel System Specifications
    145
    
    Test and Adjustment Specifications
    146
  - Special Service Tools
    147
  - Fuel System Diagram
    148
  - Fuel System Components
    149
    
    Valve Cylinder Head
    149
    
    Fuel Injection Pump
    150
  - Removal of Fuel Injection Pump
    150
    
    Installation of Fuel Injection Pump
    154
  - Checking and Adjusting Fuel Injection Timing
    159
    
    Determining Fuel Injection Timing Specification
    159
    
    Checking Fuel Injection Timing
    160
    
    Adjusting Fuel Injection Timing
    163
  - Fuel Injectors
    165
    
    Removal of Fuel Injectors
    165
    
    Testing of Fuel Injectors
    166
    
    Injectors
    167
    
    Adjusting Fuel Injector Pressure
    168
    
    Installation of the Fuel Injectors
    169
    
    Reassembly of Fuel Injectors
    169
    
    Fuel System Special Torque Chart
    170
    
    Tne98 Engine
    170
    
    Fuel System Components
    171
    
    Fuel System Components
    172
    
    Pump
    173
    
    Overview
    174
    
    Plunger Operation
    177
    
    Process
    178
    
    Fuel Injection Volume Adjustment Mechanism
    180
    
    Delivery Valve Assembly
    181
  - All - Speed Governor
    182
    
    At Start of Engine
    184
    
    During Idling
    185
    
    At Full-Load Maximum Speed Control
    186
    
    At No-Load Maximum Speed Control
    187
    
    Standard Type Automatic Timer
    189
  - Structure and Operation of Timer
    189
    
    Magnetic Valve (Stop Solenoid)
    190
    
    Removal of Fuel Injection Pump
    191
Table of Contents

192
- Figure
  194
- Installation of the Fuel Injection Pump
  194
- Checking / Adjustment of Fuel Injection Timing
  196
- Caution
  198
- Servicing the Fuel Injectors
  198
- Section 5. Cooling System
  
  203
  - Before You Begin Servicing
    203
  - Carefully Rotate the Alternator Toward the Cylinder Block While Loosening the V-Belt
    204
  - Failure to Comply May Result in Minor or
    204
  - Moderate Injury
    204
  - Pinch Hazard
    204
  - Figure
    205
    
    Cooling System Diagram
    205
    
    Introduction
    205
    
    Engine Coolant Pump Components
    206
    
    Figure
    206
    
    Engine Coolant Pump
    207
    
    Engine Coolant System Check
    207
    
    Removal of Engine Coolant Pump
    207
    
    Disassembly of Engine Coolant Pump
    209
    
    Installation of Engine Coolant Pump
    210
    
    Reassembly of Engine Coolant Pump
    210
    
    Before You Begin Servicing
    212
- Section 6. Lubrication System
  
  212
  - Introduction
    214
  - Oil Pump Service Information
    214
  - Lubrication System Diagram
    216
  - Checking Engine Oil Pressure
    217
  - Trochoid Oil Pump
    217
    
    Oil Pump Components
    217
    
    Disassembly of Oil Pump
    218
    
    Reassembly of Oil Pump
    219
    
    Before You Begin Servicing
    221
- Section 7. Starter Motor
  
  221
  - Introduction
    223
  - Starter Motor Information
    223
  - Starter Motor Specifications
    224
  - Starter Motor Troubleshooting
    225
  - Starter Motor Components
    226
  - Starter Motor
    227
    
    Disassembly of Starter Motor
    227
    
    Removal of Starter Motor
    227
    
    Cleaning and Inspection
    229
    
    Reassembly of Starter Motor
    234
    
    Check Pinion Projection Length
    235
    
    Installation of Starter Motor
    236
    
    No-Load Test
    236
    
    Special Service Tools
    237
- Section 8. Troubleshooting
  
  237
  - Compression Pressure Measurement
    238
  - Troubleshooting by Measuring Compression Pressure
    238
  - Quick Reference Table for Troubleshooting
    241
  - Troubleshooting Charts
    242
  - Wiring Diagram
    245

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