Yanmar 4TNE92-HRJ, 4TNE98-BQFLC Engine Service Manual

Description

• Model List:
  • 4TNE92-HRJ, 4TNE98-BQFLC Engine

• 1. 洋马维修手册封面.jpg
• 2. TNE_Series_Service Manual维修手册.pdf
• 2.1. Introduction
• 2.2. Yanmar Warranties
• 2.2.1. Yanmar Limited Warranty
• 2.2.1.1. What is Covered by this Warranty
• 2.2.1.2. How Long is the Warranty Period
• 2.2.1.3. What the Engine Owner Must Do
• 2.2.1.4. To Locate an Authorized Yanmar Industrial Engine
• 2.2.1.5. Dealer or Distributor
• 2.2.1.6. What Yanmar Will Do
• 2.2.1.7. What is Not Covered by this Warranty
• 2.2.1.8. Warranty Limitations
• 2.2.1.9. Warranty Modifications
• 2.2.1.10. Questions
• 2.2.1.11. Customer Registration
• 2.2.2. Yanmar Co., Ltd. Limited Emission Control
• 2.2.3. System Warranty – USA Only
• 2.2.3.1. Your Warranty Rights and Obligations
• 2.2.3.2. Manufacturers Warranty Period
• 2.2.3.3. Warranty Coverage
• 2.2.3.4. Warranted Parts
• 2.2.3.5. Exclusions
• 2.2.3.6. Owners Warranty Responsibilities
• 2.2.4. Safety Statements
• 2.2.5. Safety Precautions
• 2.2.5.1. Before You Operate
• 2.2.5.2. During Operation and Maintenance
• 2.3. General Service Information
• 2.3.1. Component Identification
• 2.3.2. Location of Labels
• 2.3.3. EPA / ARB Emission Control Regulations – USA Only
• 2.3.4. Emission Control Labels
• 2.3.4.1. EPA / ARB Labels
• 2.3.5. The 97/68/EC Directive Certified Engines
• 2.3.6. Engine Family
• 2.3.7. Function of Major Engine Components
• 2.3.8. Function of Cooling System Components
• 2.3.9. Diesel Fuel
• 2.3.9.1. Diesel Fuel Specifications
• 2.3.9.2. Filling The Fuel Tank
• 2.3.9.3. Priming the Fuel System
• 2.3.10. Engine Oil
• 2.3.10.1. Engine Oil Specifications
• 2.3.10.2. Engine Oil Viscosity
• 2.3.10.3. Checking Engine Oil
• 2.3.10.4. Adding Engine Oil
• 2.3.10.5. Engine Oil Capacity (Typical)
• 2.3.11. Engine Coolant
• 2.3.11.1. Engine Coolant Specifications
• 2.3.11.2. Filling Radiator With Engine Coolant
• 2.3.11.3. Engine Coolant Capacity (Typical)
• 2.3.12. Specifications
• 2.3.12.1. Description of Model Number
• 2.3.12.2. Engine Speed Specifications
• 2.3.12.3. Engine General Specifications
• 2.3.13. Principal Engine Specifications
• 2.3.13.1. NE92-NMH
• 2.3.13.2. NE92-NMHA
• 2.3.13.3. NE98-NMH
• 2.3.14. Engine Service Information
• 2.3.14.1. Engine Tuning
• 2.3.15. Tightening Torques for Standard Bolts and Nuts
• 2.3.16. Standard Torque Chart
• 2.3.17. Abbreviations and Symbols
• 2.3.17.1. Abbreviations
• 2.3.17.2. Symbols
• 2.3.18. Unit Conversions
• 2.3.18.1. Unit Prefixes
• 2.3.18.2. Units of Length
• 2.3.18.3. Units of Volume
• 2.3.18.4. Units of Mass
• 2.3.18.5. Units of Force
• 2.3.18.6. Units of Torque
• 2.3.18.7. Units of Pressure
• 2.3.18.8. Units of Power
• 2.3.18.9. Units of Temperature
• 2.4. Periodic Maintenance
• 2.4.1. Precautions
• 2.4.1.1. The Importance of Periodic Maintenance
• 2.4.1.2. Performing Periodic Maintenance
• 2.4.1.3. Yanmar Replacement Parts
• 2.4.1.4. Required EPA / ARB Maintenance – USA Only
• 2.4.1.5. EPA / ARB Installation Requirements – USA Only
• 2.4.1.6. Tightening Fasteners
• 2.4.2. Standard Torque Chart
• 2.4.3. Periodic Maintenance Schedule
• 2.4.4. Periodic Maintenance Procedures
• 2.4.4.1. Drain Fuel Filter / Water Separator
• 2.4.4.2. Check Fuel Hoses and Engine Coolant Hoses
• 2.4.4.3. Every 250 Hours of Operation
• 2.4.4.4. Every 500 Hours of Operation
• 2.4.4.5. Every 1000 Hours of Operation
• 2.4.4.6. Every 2000 Hours of Operation
• 2.4.4.7. Every 4000 Hours of Operation
• 2.4.5. Engine Service Information
• 2.4.5.1. Engine Body
• 2.4.5.2. Gear Train and Camshaft
• 2.4.6. Engine Special Torque Chart
• 2.4.7. Special Service Tools
• 2.4.8. Measuring Instruments
• 2.4.8.1. Before You Begin Servicing
• 2.4.9. Removal of Engine
• 2.4.9.1. Cylinder Head Components
• 2.4.9.2. Disassembly of Cylinder Head
• 2.4.9.3. Cleaning of Cylinder Head Components
• 2.4.9.4. Inspection of Cylinder Head Components
• 2.4.9.5. Assembly of Cylinder Head
• 2.4.10. Measuring and Adjusting Valve Clearance
• 2.4.10.1. Valve Clearance Measurement
• 2.4.10.2. Valve Clearance Adjustment
• 2.4.11. Drive Train and Camshaft Components
• 2.4.11.1. Disassembly of Drive Train and Camshaft Components
• 2.4.11.2. Inspection of Drive Train and Camshaft Components
• 2.4.11.3. Honing and Boring
• 2.4.11.4. Assembly of Drive Train and Camshaft Components
• 2.5. Fuel System
• 2.5.1. Fuel System Special Torque Chart
• 2.5.2. Measuring Instruments
• 2.5.3. Fuel System Components
• 2.5.4. Fuel System Diagram
• 2.5.5. Structure and Operation of Fuel Injection Pump
• 2.5.5.1. Overview
• 2.5.6. Plunger Operation
• 2.5.6.1. Process
• 2.5.6.2. Reverse Rotation Prevention Mechanism
• 2.5.6.3. Fuel Injection Volume Adjustment Mechanism
• 2.5.6.4. Delivery Valve Assembly
• 2.5.6.5. Delivery Valve Holder with Damping Valve
• 2.5.7. All -Speed Governor
• 2.5.7.1. At Start of Engine
• 2.5.7.2. During Idling
• 2.5.7.3. At Full-Load Maximum Speed Control
• 2.5.7.4. At No-Load Maximum Speed Control
• 2.5.7.5. Full-Load Position Adjustment Mechanism
• 2.5.8. Structure and Operation of Timer
• 2.5.8.1. Standard Type Automatic Timer
• 2.5.8.2. Magnetic Valve (Stop Solenoid)
• 2.5.9. Before You Begin Servicing
• 2.5.10. Removal of Fuel Injection Pump
• 2.5.11. Installation of the Fuel Injection Pump
• 2.5.12. Checking / Adjustment of Fuel Injection Timing
• 2.5.13. Servicing the Fuel Injectors
• 2.5.13.1. Removal of the Fuel Injectors
• 2.5.13.2. Inspection and Testing of the Fuel Injectors
• 2.5.13.3. Judgement Criteria on Atomization Condition
• 2.5.13.4. Installation of Fuel Injectors
• 2.6. Cooling System
• 2.6.1. Measuring Instruments
• 2.6.2. Cooling System Diagram
• 2.6.2.1. Model 4TNE92-NMHA
• 2.6.2.2. Models 4TNE92-NMH and 4TNE98-NMH
• 2.6.3. Engine Coolant Pump Components
• 2.6.3.1. Model 4TNE92-NMHA
• 2.6.3.2. Models 4TNE92-NMH and 4TNE98-NMH
• 2.6.4. Before You Begin Servicing
• 2.6.5. Engine Coolant System Check
• 2.6.6. Disassembly of Engine Coolant Pump
• 2.6.6.1. Disassembly of the 4TNE92-NMHA Coolant Pump
• 2.6.6.2. Disassembly of the 4TNE92-NMH and 4TNE98-NMH
• 2.6.6.3. Coolant Pumps
• 2.6.7. Cleaning and Inspection
• 2.6.7.1. Thermostat
• 2.6.7.2. Radiator Cap
• 2.6.8. Assembly of Engine Coolant Pump
• 2.6.8.1. Assembly of the 4TNE92-NMHA Coolant Pump
• 2.6.8.2. Assembly of the 4TNE92-NMH and 4TNE98-NMH
• 2.6.8.3. Coolant Pumps
• 2.6.8.4. Assembly of All Coolant Pump Models
• 2.7. Lubrication System
• 2.7.1. Oil Pump Service Information
• 2.7.1.1. Engine Oil Pressure – All Models
• 2.7.1.2. Outer Rotor Outside Clearance – All Models
• 2.7.1.3. Outer Rotor Side Clearance – All Models
• 2.7.1.4. Outer Rotor to Inner Rotor Tip Clearance – All Models
• 2.7.1.5. Rotor Shaft Clearance – All Models
• 2.7.2. Lubrication System Diagram
• 2.7.3. Checking Engine Oil Pressure
• 2.7.3.1. Oil Pump Components
• 2.7.3.2. Before You Begin Servicing
• 2.7.3.3. Disassembly of Oil Pump
• 2.7.3.4. Cleaning and Inspection
• 2.7.3.5. Assembly of Oil Pump
• 2.8. Starter Motor
• 2.8.1. Starter Motor Service Information
• 2.8.2. Starter Motor Troubleshooting
• 2.8.3. Starter Motor Precautions
• 2.8.4. Starter Motor Servicing
• 2.8.4.1. Starter Motor Components
• 2.8.4.2. Before You Begin
• 2.8.4.3. Starter Motor Removal
• 2.8.4.4. Starter Motor Disassembly
• 2.8.4.5. Inspection
• 2.8.4.6. Brush Holder
• 2.8.4.7. Starter Motor Assembly
• 2.8.4.8. No Load Test
• 2.8.4.9. Starter Motor Installation
• 2.9. Alternator
• 2.9.1. Alternator Service Information
• 2.9.2. Alternator Troubleshooting
• 2.9.3. Alternator Precautions
• 2.9.4. Alternator Components
• 2.9.5. Alternator Servicing
• 2.9.5.1. Before You Begin Servicing
• 2.9.5.2. Removal of Alternator
• 2.9.5.3. Disassembly of Alternator
• 2.9.5.4. Inspection
• 2.9.5.5. Assembly of Brush Holder
• 2.9.5.6. Assembly of Alternator
• 2.9.5.7. Installation of Alternator
• 2.9.5.8. Bench Test
• 2.10. Electric Wiring
• 2.10.1. Electric Wiring Precautions
• 2.10.2. Electrical Wire Resistance
• 2.10.3. Battery Cable Resistance
• 2.10.4. Electrical Wire Sizes – Voltage Drop
• 2.10.5. Conversion of AWG to European Standards
• 2.10.6. Electric Wiring Diagram
• 2.11. Troubleshooting
• 2.11.1. Special Service Tools
• 2.11.2. Troubleshooting By Measuring Compression Pressure
• 2.11.2.1. Compression Pressure Measurement Method
• 2.11.2.2. Standard Compression Pressure
• 2.11.2.3. Engine Speed and Compression Pressure (Use for Reference)
• 2.11.2.4. Measured Value and Troubleshooting
• 2.11.3. Quick Reference Table For Troubleshooting