Hitachi 3TNV, 4TNV Series Engines EWDEP-EN-01 (Preview)
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TABLE OF CONTENTS
INTRODUCTION
HITACHIWARRANTIES
SAFETY
SAFETY STATEMENTS
SAFETY PRECAUTIONS
During Operation and Maintenance
GENERAL SERVICE INFORMATION
COMPONENT IDENTIFICATION
LOCATION OF LABELS
Engine Nameplate (Typical)
EMISSION CONTROL REGULATIONS
EPA/ARB Regulations – USA Only
EMISSION CONTROL LABELS
EPA/ARB labels (Typical)
The 97/68/EC Directive Certified Engines
ENGINE FAMILY
FUNCTION OF MAJOR ENGINE COMPONENTS
FUNCTION OF COOLING SYSTEM COMPONENTS
MAIN ELECTRONIC CONTROL COMPONENTS AND FEATURES
INSTALLATION POSITION OF SENSORS
Crank Rotation Sensor
Cam Speed Sensor
New Air Temperature Sensor
EGR Temperature Sensor
Intake Temperature Sensor
Fuel Temperature Sensor (equipped on supply pump)
Cooling Water Temperature Sensor
Exhaust Temperature Sensor
Diesel Particulate Filter (DPF) Inside/Inlet Temperature Sensor
Rail Pressure Sensor
EGR Pressure Sensor
Diesel Particulate Filter (DPF) Differential Pressure Sensor
EGR Valve
Intake Air Throttles
Exhaust Air Throttles
Acceleration Sensor ( Standard)
DIESEL FUEL
Diesel Fuel Specifications
Filling The Fuel Tank
Priming the Fuel System
ENGINE LUBRICATING OIL
Engine Lubricating Oil Specifications
Engine Lubricating Oil Viscosity
Checking Engine Lubricating Oil
Adding Engine Lubricating Oil
Engine Oil Capacity (Typical)
ENGINE COOLANT
Engine Coolant Specifications
Filling Radiator with Engine Coolant
Daily Check of the Cooling System
Engine Coolant Capacity (Typical)
SPECIFICATIONS
Description of Model Number
Engine General Specifications
PRINCIPAL ENGINE SPECIFICATIONS
3TNV88C
3TNV86CT
3TNV86CHT
4TNV88C
4TNV86CT
4TNV86CHT
4TNV98C
4TNV98CT
Set Output Listed by Rotation
ENGINE SERVICE STANDARDS
TIGHTENING TORQUES FOR STANDARD BOLTS AND NUTS
ABBREVIATIONS AND SYMBOLS
UNIT CONVERSIONS
PERIODIC MAINTENANCE
BEFORE YOU BEGINSERVICING
INTRODUCTION
The Importance of Periodic Maintenance
Performing Periodic Maintenance
Replacement Parts
Required EPA/ARB Maintenance USA Only
EPA/ARB Installation Requirements USA Only
PERIODIC MAINTENANCE SCHEDULE
PERIODIC MAINTENANCE PROCEDURES
After Initial 50 Hours of Operation
Every 50 Hours of Operation
Every 250 Hours of Operation
Every 500 Hours of Operation
Every 1000 Hours of Operation
Every 1500 Hours of Operation
Every 2000 Hours of Operation
Every 3000 Hours of Operation
At 6000 Hours of Operation
ENGINE
BEFORE YOU BEGIN SERVICING
INTRODUCTION
CYLINDER HEAD SPECIFICATIONS
Adjustment Specifications
Cylinder Head
Intake/Exhaust Valve and Guide
Push Rod
Rocker Arm and Shaft
Valve Spring
CAMSHAFT AND TIMING GEAR TRAIN SPECIFICATIONS
Camshaft
Idler Gear Shaft and Bushing
Timing Gear Backlash
CRANKSHAFT AND PISTON SPECIFICATIONS
Crankshaft
Thrust Bearing
Piston
Piston Ring
Connecting Rod
Tappet
CYLINDER BLOCK SPECIFICATIONS
Cylinder Block
SPECIAL TORQUE CHART
Torque for Bolts and Nuts
SPECIAL SERVICE TOOLS
MEASURING INSTRUMENTS
CYLINDER HEAD
Cylinder Head Components
Disassembly of Cylinder Head
Removing the Glow Plugs
Removal of Cylinder Head Cover
Removal of Rocker Arm Assembly
Disassembly of Rocker Arm Assembly
Removal of Cylinder Head
Removal of Intake/exhaust Valves
Removal of Valve Guides
Cleaning of Cylinder Head Components
Inspection of Cylinder Head Components
Inspection of Push Rods
Inspection of Rocker Arm Assembly
Inspection of Valve Guides
Inspection of Cylinder Head
Inspection of Intake and Exhaust Valves
Inspection of Valve Springs
Reassembly of Cylinder Head
MEASURING AND ADJUSTING VALVE CLEARANCE
CRANKSHAFT AND CAMSHAFT COMPONENTS
Disassembly of Engine
Disassembly of Camshaft and Timing Components
Disassembly of Crankshaft and Piston Components
Inspection of Crankshaft and Camshaft Components
Honing and Boring
Reassembly of Crankshaft and Piston Components
Reassembly of Camshaft and Timing Components
Final Reassembly of Engine
EGR SYSTEM
EGR System Configuration
Disassembly of EGR System
Cleaning the EGR Cooler (Water Side/Exhaust Passage Blower)
Cleaning the EGR Pipe and Other Connecting Elbows
Check, Clean, and Test EGR Valve
Cleaning the EGR Lead Valves
Assembling around the EGR Valve
INTAKE THROTTLE
Precautions for Handling the Intake Throttle
EXHAUST THROTTLE
Checking the Operation of Exhaust Throttle
FUEL SYSTEM
BEFORE YOU BEGIN SERVICING
SYSTEM STRUCTURE
FUEL SYSTEM SPECIFICATIONS
Torque Chart for Major Bolts and Nuts
FUEL SYSTEM DIAGRAM
FUEL SYSTEM COMPONENTS
Removal of Injector
Reassembly of injector
Removal of Common Rail
Reassembly of Common Rail
Removal of Supply Pump
Reassembly of Supply Pump
COOLING SYSTEM
BEFORE YOU BEGIN SERVICING
INTRODUCTION
COOLING SYSTEM DIAGRAM
ENGINE COOLANT PUMP COMPONENTS
ENGINE COOLANT SYSTEM CHECK
ENGINE COOLANT PUMP
Removal of Engine Coolant Pump
Disassembly of Engine Coolant Pump
Cleaning and Inspection
Reassembly of Engine Coolant Pump
Installation of Engine Coolant Pump
LUBRICATION SYSTEM
BEFORE YOU BEGIN SERVICING
INTRODUCTION
OIL PUMP SERVICE INFORMATION
LUBRICATION SYSTEM DIAGRAM
CHECKING ENGINE LUBRICATING OIL PRESSURE
OIL PUMP COMPONENTS
3TNV88C, 3TNV86CT, 3TNV86CHT, 4TNV88C, 4TNV86CT, 4TNV86CHT
Disassembly of Oil Pump
Cleaning and Inspection
Reassembly of Oil Pump
4TNV98C, 4TNV98CT (Trochoid Oil Pump)
Disassembly of Oil Pump
Cleaning and Inspection
Reassembly of Oil Pump
TURBOCHARGER
BEFORE YOU BEGIN SERVICING
INTRODUCTION
SPECIFICATIONS
Turbocharger Service Information
TROUBLESHOOTING
TURBOCHARGER COMPONENTS
TURBOCHARGER COMPONENT FUNCTIONS
Structure of Turbocharger
Role of Waste Gate
PERIODIC INSPECTION
Visual Inspection
Inspection of Rotor Rotation
Checking Rotor Play
Waste Gate Valve Test
Waste Gate Actuator Leak Test
REMOVAL AND INSTALLATION OF TURBOCHARGER
Removal of Turbocharger
Installation of Turbocharger
CLEANING PROCEDURE
STARTER MOTOR
BEFORE YOU BEGIN SERVICING
INTRODUCTION
STARTER MOTOR INFORMATION
3TNV88C to 4TNV86CHT – Standard and Optional
4TNV98C and 4TNV98CT – Standard and Optional
STARTER MOTOR SPECIFICATIONS
STARTER MOTOR TROUBLESHOOTING
STARTER MOTOR COMPONENTS
STARTER MOTOR
Removal of Starter Motor
Disassembly of Starter Motor
Cleaning and Inspection
Reassembly of Starter Motor
Check Pinion Projection Length
No-Load Test
Installation of Starter Motor
ALTERNATOR
BEFORE YOU BEGIN SERVICING
INTRODUCTION
DYNAMO AND ALTERNATOR INFORMATION
3TNV88C to 4TNV98CT – Standard and Optional Dynamos
3TNV88C to 4TNV98CT – Standard and Optional Alternators
ALTERNATOR SPECIFICATIONS
DYNAMO SPECIFICATIONS
ALTERNATOR TROUBLESHOOTING
ALTERNATOR COMPONENTS
ALTERNATOR WIRING DIAGRAM
ALTERNATOR STANDARD OUTPUT
ALTERNATOR
Removal of Alternator
Disassembly of Alternator
Reassembly of Alternator
Installation of Alternator
DYNAMO COMPONENT LOCATION
DYNAMO WIRING DIAGRAM
OPERATION OF DYNAMO
DYNAMO STANDARD OUTPUT
TESTING OF DYNAMO
Testing Stator Coil Continuity
Testing Stator Coil Short-to-Ground
Testing Dynamo Regulated Output
DYNAMO
Removal of Dynamo
Disassembly of Dynamo
Reassembly of Dynamo
Installation of Dynamo
ELECTRONIC CONTROL SYSTEM
BEFORE YOU BEGIN SERVICING
INTRODUCTION
SYSTEM STRUCTURE
Diesel Particulate Filter (DPF)
HOW TO REMOVE AND REATTACH THE DIESEL PARTICULATE FILTER (DPF)
SF AND DPF MAINTENANCE KIT
TROUBLESHOOTING OF ELECTRONIC CONTROL SYSTEM
Fault Detection Capability
SMARTASSIST-DIRECT (SA-D)
REPLACEMENT OF COMPONENTS
ELECTRONIC CONTROL HARNESS CONNECTIONS
ELECTRIC WIRING
ELECTRIC WIRING PRECAUTIONS
ELECTRICAL WIRE RESISTANCE
BATTERY CABLE RESISTANCE
ELECTRICAL WIRE SIZES – VOLTAGE DROP
CONVERSION OF AWG TO EUROPEAN STANDARDS
FAILURE DIAGNOSIS
SPECIAL SERVICE TOOLS
TROUBLESHOOTING BY MEASURING COMPRESSION PRESSURE
Compression Pressure Inspection Procedures
Attaching the Injector
Standard Compression Pressure (Reference Value)
Engine Speed And Compression Pressure (Use For Reference)
MEASURED VALUE AND TROUBLESHOOTING
QUICK REFERENCE TABLE FOR TROUBLESHOOTING
Failure Diagnostic List
SERVICE MANUAL REVISION REQUEST FORM
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