Yanmar 4TNE92, 4TNE94L, 4TNE98 Industrial Engine Service Manual

Description

• Model List:
  • 4TNE92, 4TNE94L, 4TNE98 Industrial Engine

• 1. Introduction
• 2. Yanmar Warranties
• 2.1. Yanmar Limited Warranty
• 2.1.1. What is Covered by this Warranty
• 2.1.2. How Long is the Warranty Period
• 2.1.3. What the Engine Owner Must Do
• 2.1.4. To Locate an Authorized Yanmar Industrial Engine
• 2.1.5. Dealer or Distributor
• 2.1.6. What Yanmar Will Do
• 2.1.7. What is Not Covered by this Warranty
• 2.1.8. Warranty Limitations
• 2.1.9. Warranty Modifications
• 2.1.10. Questions
• 2.1.11. Customer Registration
• 2.2. Yanmar Co., Ltd. Limited Emission Control
• 2.3. System Warranty – USA Only
• 2.3.1. Your Warranty Rights and Obligations
• 2.3.1.1. California
• 2.3.1.2. All States
• 2.3.2. Manufacturers Warranty Period
• 2.3.3. Warranty Coverage
• 2.3.4. Warranted Systems / Parts Covered by this Warranty
• 2.3.5. Exclusions
• 2.3.6. Owners Warranty Responsibilities
• 2.4. Safety Statements
• 2.5. Safety Precautions
• 2.5.1. Before You Operate
• 2.5.2. During Operation and Maintenance
• 3. General Service Information
• 3.1. Component Identification
• 3.2. Location of Labels
• 3.3. EPA / ARB Emission Control Regulations – USA Only
• 3.4. Emission Control Labels
• 3.4.1. EPA / CARB Labels (Typical)
• 3.5. The 97/68/EC Directive Certified Engines
• 3.6. Engine Family
• 3.7. Function of Major Engine Components
• 3.8. Function of Cooling System Components
• 3.9. Diesel Fuel
• 3.9.1. Diesel Fuel Specifications
• 3.9.1.1. Additional Technical Fuel Requirements
• 3.9.1.2. Bio-Diesel Fuels
• 3.9.2. Filling The Fuel Tank
• 3.9.3. Priming the Fuel System
• 3.10. Engine Oil
• 3.10.1. Engine Oil Specifications
• 3.10.1.1. Service Categories
• 3.10.1.2. Definitions
• 3.10.1.3. Additional Technical Engine oil Requirements
• 3.10.2. Engine Oil Viscosity
• 3.10.3. Checking Engine Oil
• 3.10.4. Adding Engine Oil
• 3.10.5. Engine Oil Capacity (Typical)
• 3.11. Engine Coolant
• 3.11.1. Engine Coolant Specifications
• 3.11.1.1. Alternative Engine Coolant
• 3.11.1.2. Additional Technical Coolant Specifications
• 3.11.2. Filling Radiator With Engine Coolant
• 3.11.3. Engine Coolant Capacity (Typical)
• 3.12. Specifications
• 3.12.1. Description of Model Number
• 3.12.2. Engine Speed Specifications
• 3.12.3. Engine General Specifications
• 3.13. Principal Engine Specifications
• 3.13.1. NE92 EPA Tier2 Tier3
• 3.13.2. NE94L EPA Tier2
• 3.13.3. NE94L EPA Tier3
• 3.13.4. NE98 EPA Tier2
• 3.13.5. NE98 EPA Tier3
• 3.14. Engine Service Information
• 3.14.1. Engine Tuning
• 3.15. Tightening Torques for Standard Bolts and Nuts
• 3.16. Standard Torque Chart
• 3.17. Abbreviations and Symbols
• 3.17.1. Abbreviations
• 3.17.2. Symbols
• 3.18. Unit Conversions
• 3.18.1. Unit Prefixes
• 3.18.2. Units of Length
• 3.18.3. Units of Volume
• 3.18.4. Units of Mass
• 3.18.5. Units of Force
• 3.18.6. Units of Torque
• 3.18.7. Units of Pressure
• 3.18.8. Units of Power
• 3.18.9. Units of Temperature
• 4. Periodic Maintenance
• 4.1. Precautions
• 4.1.1. The Importance of Periodic Maintenance
• 4.1.2. Performing Periodic Maintenance
• 4.1.3. Yanmar Replacement Parts
• 4.1.4. Required EPA / ARB Maintenance – USA Only
• 4.1.5. EPA / ARB Installation Requirements – USA Only
• 4.1.6. Tightening Fasteners
• 4.2. Standard Torque Chart
• 4.3. Periodic Maintenance Schedule
• 4.4. Periodic Maintenance Procedures
• 4.4.1. Drain Fuel Filter / Water Separator
• 4.4.2. Check Fuel Hoses and Engine Coolant Hoses
• 4.4.3. Every 250 Hours of Operation
• 4.4.3.1. Check and Clean Radiator Fins
• 4.4.3.2. Check and Adjust Cooling Fan V-belt
• 4.4.3.3. Check Battery
• 4.4.3.4. Clean Air Cleaner Element
• 4.4.4. Every 500 Hours of Operation
• 4.4.4.1. Replace Engine Oil and Engine Oil Filter
• 4.4.4.2. Check and Adjust the Governor Lever and Engine Speed Control
• 4.4.5. Every 1000 Hours of Operation
• 4.4.5.1. Adjust Intake / Exhaust Valve Clearance
• 4.4.5.2. Clean Fuel Filter / Water Separator
• 4.4.5.3. Replace Fuel Filter
• 4.4.6. Every 2000 Hours of Operation
• 4.4.6.1. Replace Air Cleaner Element
• 4.4.6.2. Inspect Clean and Test Fuel Injectors
• 4.4.7. Every 4000 Hours of Operation
• 4.4.7.1. Drain, Flush, and Re-fill the Coolant System with New Coolant
• 4.4.7.2. Replace Fuel Hoses and Engine Coolant Hoses
• 4.5. Engine Service Information
• 4.5.1. Engine Body
• 4.5.1.1. Cylinder Head
• 4.5.1.2. Intake / Exhaust Valve and Guide
• 4.5.1.3. Valve Spring
• 4.5.1.4. Rocker Arm and Shaft
• 4.5.1.5. Push Rod
• 4.5.2. Gear Train and Camshaft
• 4.5.2.1. Camshaft
• 4.5.2.2. Idler Gear Shaft and Bushing
• 4.5.2.3. Backlash of Each Gear
• 4.5.2.4. Cylinder Block
• 4.5.2.5. Crankshaft
• 4.5.2.6. Thrust Bearing
• 4.5.2.7. Piston Ring
• 4.5.2.8. Connecting Rod
• 4.6. Engine Special Torque Chart
• 4.7. Special Service Tools
• 4.8. Measuring instruments
• 4.8.1. Before You Begin Servicing
• 4.9. Removal of Engine
• 4.9.1. Cylinder Head Components
• 4.9.2. Disassembly of Cylinder Head
• 4.9.2.1. Removal of Glow Plugs
• 4.9.2.2. Removal of Valve Cover
• 4.9.2.3. Removal of Rocker Arm Assembly
• 4.9.2.4. Disassembly of Rocker Arm Assembly
• 4.9.2.5. Removal of Cylinder Head
• 4.9.2.6. Removal of Intake / Exhaust Valves
• 4.9.2.7. Removal of Valve Guides
• 4.9.3. Cleaning of Cylinder Head Components
• 4.9.4. Inspection of Cylinder Head Components
• 4.9.4.1. Inspection of Push Rods
• 4.9.4.2. Inspection of Rocker Arm Assembly
• 4.9.4.3. Inspection of Valve Guides
• 4.9.4.4. Inspection of Cylinder Head
• 4.9.4.5. Inspection of Intake and Exhaust Valves
• 4.9.4.6. Inspection of Valve Springs
• 4.9.5. Assembly of Cylinder Head
• 4.9.5.1. Assembly of Valve Guides
• 4.9.5.2. Assembly of Intake and Exhaust Valves
• 4.9.5.3. Assembly of Cylinder Head
• 4.9.5.4. Assembly of Rocker Arm Assembly
• 4.9.5.5. Assembly of the Valve Cover
• 4.9.5.6. Assembly of Glow Plugs
• 4.10. Measuring and Adjusting Valve Clearance
• 4.10.1. Valve Clearance Measurement
• 4.10.2. Valve Clearance Adjustment
• 4.11. Drive Train and Camshaft Components
• 4.11.1. Disassembly of Drive Train and Camshaft Components
• 4.11.1.1. Removal of Oil Pan
• 4.11.1.2. Removal of Oil Sump Pump
• 4.11.1.3. Removal of Timing Gears
• 4.11.1.4. Removal of Pistons
• 4.11.1.5. Removal of Crankshaft
• 4.11.1.6. Removal of Camshaft
• 4.11.1.7. Removal of Gear Case
• 4.11.2. Inspection of Drive Train and Camshaft Components
• 4.11.2.1. Inspection of Cylinder Block
• 4.11.2.2. Inspection of Pistons
• 4.11.2.3. Inspection of Piston Pin
• 4.11.2.4. Inspection of Connecting Rod
• 4.11.2.5. Inspection of Tappets
• 4.11.2.6. Inspection of Crankshaft
• 4.11.2.7. Inspection of Camshaft
• 4.11.2.8. Inspection of Camshaft Bushings
• 4.11.2.9. Inspection of Idler Gear and Shaft
• 4.11.3. Honing and Boring
• 4.11.4. Assembly of Drive Train and Camshaft Components
• 4.11.4.1. Assembly of Pistons
• 4.11.4.2. Installation of Gear Case
• 4.11.4.3. Installation of Crankshaft
• 4.11.4.4. Installation of Pistons
• 4.11.4.5. Installation of Camshaft
• 4.11.4.6. Installation of Timing Gears
• 4.11.4.7. Installation of Gear Case Cover
• 4.11.4.8. Installation of Oil Sump Pump
• 4.11.4.9. Installation of Oil Pan
• 5. Fuel System
• 5.1. Fuel System Special Torque Chart
• 5.2. Measuring Instruments
• 5.3. Fuel System Components
• 5.4. Fuel System Diagram
• 5.5. Structure and Operation of Fuel Injection Pump
• 5.5.1. Overview
• 5.5.1.1. Governor
• 5.5.1.2. Feed Pump (Vane Type)
• 5.5.1.3. Regulating Valve
• 5.6. Plunger Operation
• 5.6.1. Process
• 5.6.1.1. Suction Process
• 5.6.1.2. Injection Process
• 5.6.1.3. End of Injection
• 5.6.1.4. Uniform Pressure Process
• 5.6.2. Reverse Rotation Prevention Mechanism
• 5.6.3. Fuel Injection Volume Adjustment Mechanism
• 5.6.4. Delivery Valve Assembly
• 5.6.5. Delivery Valve Holder with Damping Valve
• 5.7. All -Speed Governor
• 5.7.1. At Start of Engine
• 5.7.2. During Idling
• 5.7.3. At Full-Load Maximum Speed Control
• 5.7.4. At No-Load Maximum Speed Control
• 5.7.5. Full-Load Position Adjustment Mechanism
• 5.8. Structure and Operation of Timer
• 5.8.1. Standard Type Automatic Timer
• 5.8.2. Magnetic Valve (Stop Solenoid)
• 5.8.3. Cold Start Device (CSD)
• 5.8.3.1. Necessity of CSD
• 5.8.3.2. CSD Coupler Shape
• 5.8.3.3. Coolant Temperature Sensor
• 5.8.3.4. Controller External View (Optional)
• 5.8.3.5. Connecting Diagram
• 5.8.3.6. Actuation Chart
• 5.8.3.7. Function
• 5.8.3.8. Relay Characteristics
• 5.9. Before You Begin Servicing
• 5.10. Removal of Fuel Injection Pump
• 5.11. Installation of the Fuel Injection Pump
• 5.12. Checking / Adjustment of Fuel Injection Timing
• 5.13. Servicing the Fuel Injectors
• 5.13.1. Removal of the Fuel Injectors
• 5.13.2. Inspection and Testing of the Fuel Injectors
• 5.13.2.1. Test Procedure Using a Nozzle Tester
• 5.13.3. Judgement Criteria on Atomization Condition
• 5.13.3.1. Cleaning of Nozzle
• 5.13.4. Installation of Fuel Injectors
• 6. Cooling System
• 6.1. Measuring Instruments
• 6.2. Cooling System Diagram
• 6.3. Engine Coolant Pump Components
• 6.4. Before You Begin Servicing
• 6.5. Engine Coolant System Check
• 6.6. Disassembly of Engine Coolant Pump
• 6.6.1. Disassembly of the Coolant Pumps
• 6.7. Cleaning and Inspection
• 6.7.1. Thermostat
• 6.7.2. Radiator Cap
• 6.8. Assembly of Engine Coolant Pump
• 6.8.1. Assembly of All Coolant Pump Models
• 7. Lubrication System
• 7.1. Oil Pump Service Information
• 7.1.1. Engine Oil Pressure – All Models
• 7.1.2. Outer Rotor Outside Clearance – All Models
• 7.1.3. Outer Rotor Side Clearance – All Models
• 7.1.4. Outer Rotor to Inner Rotor Tip Clearance – All Models
• 7.1.5. Rotor Shaft Clearance – All Models
• 7.2. Lubrication System Diagram
• 7.3. Checking Engine Oil Pressure
• 7.3.1. Oil Pump Components
• 7.3.2. Before You Begin Servicing
• 7.3.3. Disassembly of Oil Pump
• 7.3.4. Cleaning and Inspection
• 7.3.4.1. Check Outer Rotor Outside Clearance
• 7.3.4.2. Outer Rotor to Inner Rotor Tip Clearance
• 7.3.4.3. Check Outer Rotor Side Clearance
• 7.3.4.4. Check Rotor Shaft Clearance
• 7.3.5. Assembly of Oil Pump
• 8. Starter Motor
• 8.1. Starter Motor Service Information
• 8.2. Starter Motor Troubleshooting
• 8.3. Starter Motor Precautions
• 8.4. Starter Motor Servicing
• 8.4.1. Starter Motor Components
• 8.4.2. Before You Begin
• 8.4.3. Starter Motor Removal
• 8.4.4. Starter Motor Disassembly
• 8.4.5. Inspection
• 8.4.5.1. Armature
• 8.4.5.2. Field Coil
• 8.4.6. Brush Holder
• 8.4.6.1. Magnetic Switch
• 8.4.6.2. Pinion Clutch Assembly
• 8.4.7. Starter Motor Assembly
• 8.4.7.1. Check Pinion Projection Length
• 8.4.8. No Load Test
• 8.4.9. Starter Motor Installation
• 9. Alternator
• 9.1. Alternator Service Information
• 9.2. Alternator Troubleshooting
• 9.3. Alternator Precautions
• 9.4. Alternator Components
• 9.5. Alternator Servicing
• 9.5.1. Before You Begin Servicing
• 9.5.2. Removal of Alternator
• 9.5.3. Disassembly of Alternator
• 9.5.4. Inspection
• 9.5.4.1. Stator Coil
• 9.5.4.2. Rectifier
• 9.5.4.3. IC Regulator
• 9.5.5. Assembly of Brush Holder
• 9.5.6. Assembly of Alternator
• 9.5.7. Installation of Alternator
• 9.5.8. Bench Test
• 9.5.8.1. Test Wiring
• 9.5.8.2. Regulated Voltage Check
• 9.5.8.3. No Load Test
• 9.5.8.4. Output Test
• 10. Electric Wiring
• 10.1. Electric Wiring Precautions
• 10.2. Electrical Wire Resistance
• 10.3. Battery Cable Resistance
• 10.4. Electrical Wire Sizes – Voltage Drop
• 10.5. Conversion of AWG to European Standards
• 10.6. Electric Wiring Diagram (Reference)
• 11. Troubleshooting
• 11.1. Special Service Tools
• 11.2. Troubleshooting By Measuring Compression Pressure
• 11.2.1. Compression Pressure Measurement Method
• 11.2.2. Standard Compression Pressure
• 11.2.3. Engine Speed and Compression Pressure (Use for Reference)
• 11.2.4. Measured Value and Troubleshooting
• 11.3. Quick Reference Table For Troubleshooting
• 12. Back Cover