EP Forklift Yanmar Engine 4TNE92 4TNE94L 4TNE98 Service Manual – PDF DOWNLOAD

EP Forklift Yanmar Engine 4TNE92 4TNE94L 4TNE98 Service Manual – PDF DOWNLOAD

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EP Forklift Yanmar Engine 4TNE92 4TNE94L 4TNE98 Service Manual – PDF DOWNLOAD

Language : English
Pages : 279
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

EP Forklift Yanmar Engine 4TNE92 4TNE94L 4TNE98 Service Manual – PDF DOWNLOAD

COVER........................................................................  1
	COVER....................................................................  2
Introduction.................................................................  8
Yanmar Warranties............................................................ 10
	Yanmar Limited Warranty.................................................. 12
		What is Covered by this Warranty?.................................... 12
		How Long is the Warranty Period?..................................... 12
		What the Engine Owner Must Do:....................................... 12
		To Locate an Authorized Yanmar Industrial Engine..................... 12
		Dealer or Distributor:............................................... 12
		What Yanmar Will Do:................................................. 12
		What is Not Covered by this Warranty?................................ 13
		Warranty Limitations:................................................ 13
		Warranty Modifications:.............................................. 13
		Questions:........................................................... 13
		Customer Registration................................................ 13
	Yanmar Co., Ltd. Limited Emission Control................................ 14
	System Warranty - USA Only............................................... 14
		Your Warranty Rights and Obligations:................................ 14
			California....................................................... 14
			All States....................................................... 14
		Manufacturer’s Warranty Period:...................................... 14
		Warranty Coverage:................................................... 15
		Warranted Systems / Parts Covered by this Warranty:.................. 15
		Exclusions:.......................................................... 16
		Owner’s Warranty Responsibilities:................................... 16
Safety....................................................................... 18
	Safety Statements........................................................ 18
	Safety Precautions....................................................... 19
		Before You Operate................................................... 19
		During Operation and Maintenance..................................... 19
General Service Information.................................................. 32
	Component Identification................................................. 34
	Location of Labels....................................................... 34
	EPA / ARB Emission Control Regulations - USA Only........................ 35
	Emission Control Labels.................................................. 35
		EPA / ARB Labels..................................................... 35
	The 97/68/EC Directive Certified Engines................................. 35
	Engine Family............................................................ 36
	Function of Major Engine Components...................................... 37
	Function of Cooling System Components.................................... 39
	Diesel Fuel.............................................................. 40
		Diesel Fuel Specifications........................................... 40
			Additional Technical Fuel Requirements........................... 40
			Bio-Diesel Fuels................................................. 40
		Filling The Fuel Tank................................................ 41
		Priming the Fuel System.............................................. 43
	Engine Oil............................................................... 45
		Engine Oil Specifications............................................ 45
			Service Categories............................................... 45
			Definitions...................................................... 45
			Additional Technical Engine oil Requirements:.................... 45
		Engine Oil Viscosity................................................. 45
		Checking Engine Oil.................................................. 46
		Adding Engine Oil.................................................... 46
		Engine Oil Capacity (Typical)........................................ 46
	Engine Coolant........................................................... 47
		Engine Coolant Specifications........................................ 47
			Alternative Engine Coolant....................................... 47
			Additional Technical Coolant Specifications:..................... 48
		Filling Radiator With Engine Coolant................................. 48
		Engine Coolant Capacity (Typical).................................... 49
	Specifications........................................................... 50
		Description of Model Number.......................................... 50
		Engine Speed Specifications.......................................... 50
		Engine General Specifications........................................ 50
	Principal Engine Specifications.......................................... 51
		4TNE92 EPA Tier2 & Tier3............................................. 51
		4TNE94L EPA Tier2 Only............................................... 52
		4TNE98 EPA Tier2..................................................... 53
		4TNE98 EPA Tier3..................................................... 54
	Engine Service Information............................................... 55
		Engine Tuning........................................................ 55
	Tightening Torques for Standard Bolts and Nuts........................... 56
	Standard Torque Chart.................................................... 57
	Abbreviations and Symbols................................................ 58
		Abbreviations........................................................ 58
		Symbols.............................................................. 58
	Unit Conversions......................................................... 59
		Unit Prefixes........................................................ 59
			Prefix........................................................... 59
			Symbol........................................................... 59
			Power............................................................ 59
		Units of Length...................................................... 59
		Units of Volume...................................................... 59
		Units of Mass........................................................ 59
		Units of Force....................................................... 59
		Units of Torque...................................................... 59
		Units of Pressure.................................................... 59
		Units of Power....................................................... 59
		Units of Temperature................................................. 59
Periodic Maintenance......................................................... 60
	Precautions.............................................................. 75
		The Importance of Periodic Maintenance............................... 75
		Performing Periodic Maintenance...................................... 75
		Yanmar Replacement Parts............................................. 75
		Required EPA / ARB Maintenance - USA Only............................ 75
		EPA / ARB Installation Requirements - USA Only....................... 75
		Tightening Fasteners................................................. 76
	Standard Torque Chart.................................................... 76
	Periodic Maintenance Schedule............................................ 76
	Periodic Maintenance Procedures.......................................... 78
		Daily................................................................ 78
			Drain Fuel Filter / Water Separator.............................. 78
			Check Fuel Hoses and Engine Coolant Hoses........................ 79
		Every 250 Hours of Operation......................................... 80
			Check and Clean Radiator Fins.................................... 80
			Check and Adjust Cooling Fan V-belt.............................. 81
			Check Battery.................................................... 82
			Clean Air Cleaner Element........................................ 83
		Every 500 Hours of Operation......................................... 85
			Replace Engine Oil and Engine Oil Filter......................... 85
			Check and Adjust the Governor Lever and Engine Speed Control..... 87
		Every 1000 Hours of Operation........................................ 88
			Adjust Intake / Exhaust Valve Clearance.......................... 88
			Clean Fuel Filter / Water Separator.............................. 88
			Replace Fuel Filter.............................................. 90
		Every 2000 Hours of Operation........................................ 93
			Replace Air Cleaner Element...................................... 93
			Inspect Clean and Test Fuel Injectors............................ 93
		Every 4000 Hours of Operation........................................ 94
			Drain, Flush, and Re-fill the Coolant System with New Coolant.... 94
			Replace Fuel Hoses and Engine Coolant Hoses...................... 95
Engine....................................................................... 96
	Engine Service Information...............................................100
		Engine Body..........................................................100
			Cylinder Head....................................................100
			Intake / Exhaust Valve and Guide.................................100
			Valve Spring.....................................................101
			Rocker Arm and Shaft.............................................101
			Push Rod.........................................................101
		Gear Train and Camshaft..............................................102
			Camshaft.........................................................102
			Idler Gear Shaft and Bushing.....................................102
			Backlash of Each Gear............................................103
			Cylinder Block...................................................103
			Crankshaft.......................................................103
			Thrust Bearing...................................................104
			Piston...........................................................104
			Piston Ring......................................................105
			Connecting Rod...................................................105
			Tappet...........................................................106
	Engine Special Torque Chart..............................................107
	Special Service Tools....................................................108
	Measuring instruments....................................................110
		Before You Begin Servicing...........................................113
	Removal of Engine........................................................114
		Cylinder Head Components.............................................115
		Disassembly of Cylinder Head.........................................116
			Removal of Glow Plugs............................................117
			Removal of Valve Cover...........................................117
			Removal of Rocker Arm Assembly...................................117
			Disassembly of Rocker Arm Assembly...............................118
			Removal of Cylinder Head.........................................118
			Removal of Intake / Exhaust Valves...............................119
			Removal of Valve Guides..........................................119
		Cleaning of Cylinder Head Components.................................120
		Inspection of Cylinder Head Components...............................120
			Inspection of Push Rods..........................................120
			Inspection of Rocker Arm Assembly................................120
			Inspection of Valve Guides.......................................121
			Inspection of Cylinder Head......................................121
			Inspection of Intake and Exhaust Valves..........................121
			Inspection of Valve Springs......................................123
		Assembly of Cylinder Head............................................123
			Assembly of Valve Guides.........................................123
			Assembly of Intake and Exhaust Valves............................124
			Assembly of Cylinder Head........................................125
			Assembly of Rocker Arm Assembly..................................125
			Assembly of the Valve Cover......................................126
			Assembly of Glow Plugs...........................................126
	Measuring and Adjusting Valve Clearance..................................127
		Valve Clearance Measurement..........................................127
		Valve Clearance Adjustment...........................................128
	Drive Train and Camshaft Components......................................129
		Disassembly of Drive Train and Camshaft Components...................130
			Removal of Oil Pan...............................................131
			Removal of Oil Sump Pump.........................................131
			Removal of Timing Gears..........................................131
			Removal of Pistons...............................................132
			Removal of Crankshaft............................................133
			Removal of Camshaft..............................................134
			Removal of Gear Case.............................................135
		Inspection of Drive Train and Camshaft Components....................135
			Inspection of Cylinder Block.....................................135
			Inspection of Pistons............................................139
			Inspection of Piston Pin.........................................139
			Inspection of Connecting Rod.....................................140
			Inspection of Tappets............................................140
			Inspection of Crankshaft.........................................140
			Inspection of Camshaft...........................................141
			Inspection of Camshaft Bushings..................................142
			Inspection of Idler Gear and Shaft...............................142
		Honing and Boring....................................................143
		Assembly of Drive Train and Camshaft Components......................144
			Assembly of Pistons..............................................144
			Installation of Gear Case........................................145
			Installation of Crankshaft.......................................145
			Installation of Pistons..........................................146
			Installation of Camshaft.........................................147
			Installation of Timing Gears.....................................147
			Installation of Gear Case Cover..................................148
			Installation of Oil Sump Pump....................................148
			Installation of Oil Pan..........................................148
Fuel System..................................................................150
	Fuel System Special Torque Chart.........................................152
	Measuring Instruments....................................................152
	Fuel System Components...................................................155
	Fuel System Diagram......................................................156
	Structure and Operation of Fuel Injection Pump...........................157
		Overview.............................................................158
			Pump.............................................................158
			Governor.........................................................158
			Timer............................................................159
			Feed Pump (Vane Type)............................................159
			Regulating Valve.................................................160
	Plunger Operation........................................................161
		Process..............................................................162
			Suction Process..................................................162
			Injection Process................................................162
			End of Injection.................................................163
			Uniform Pressure Process.........................................163
		Reverse Rotation Prevention Mechanism................................164
		Fuel Injection Volume Adjustment Mechanism...........................164
		Delivery Valve Assembly..............................................165
		Delivery Valve Holder with Damping Valve.............................165
	All -Speed Governor......................................................166
		At Start of Engine...................................................168
		During Idling........................................................169
		At Full-Load Maximum Speed Control...................................170
		At No-Load Maximum Speed Control.....................................171
		Full-Load Position Adjustment Mechanism..............................172
	Structure and Operation of Timer.........................................173
		Standard Type Automatic Timer........................................173
		Magnetic Valve (Stop Solenoid).......................................174
	Before You Begin Servicing...............................................175
	Removal of Fuel Injection Pump...........................................176
	Installation of the Fuel Injection Pump..................................179
	Checking / Adjustment of Fuel Injection Timing...........................181
	Servicing the Fuel Injectors.............................................183
		Removal of the Fuel Injectors........................................183
		Inspection and Testing of the Fuel Injectors.........................184
			Test Procedure Using a Nozzle Tester.............................184
		Judgement Criteria on Atomization Condition..........................186
			Cleaning of Nozzle...............................................187
		Installation of Fuel Injectors.......................................187
Cooling System...............................................................188
	Measuring Instruments....................................................192
	Cooling System Diagram...................................................193
	Engine Coolant Pump Components...........................................194
	Before You Begin Servicing...............................................195
	Engine Coolant System Check..............................................196
	Disassembly of Engine Coolant Pump.......................................197
		Disassembly of the Coolant Pumps.....................................198
	Cleaning and Inspection..................................................199
		Thermostat...........................................................199
		Radiator Cap.........................................................199
	Assembly of Engine Coolant Pump..........................................199
		Assembly of All Coolant Pump Models..................................200
Lubrication System...........................................................202
	Oil Pump Service Information.............................................206
		Engine Oil Pressure - All Models.....................................206
		Outer Rotor Outside Clearance - All Models...........................206
		Outer Rotor Side Clearance - All Models..............................206
		Outer Rotor to Inner Rotor Tip Clearance - All Models................206
		Rotor Shaft Clearance - All Models...................................206
	Lubrication System Diagram...............................................207
	Checking Engine Oil Pressure.............................................208
		Oil Pump Components..................................................208
		Before You Begin Servicing...........................................208
		Disassembly of Oil Pump..............................................210
		Cleaning and Inspection..............................................210
			Check Outer Rotor Outside Clearance..............................211
			Outer Rotor to Inner Rotor Tip Clearance.........................211
			Check Outer Rotor Side Clearance.................................211
			Check Rotor Shaft Clearance......................................211
		Assembly of Oil Pump.................................................212
Starter Motor................................................................214
	Starter Motor Service Information........................................218
	Starter Motor Troubleshooting............................................219
	Starter Motor Precautions................................................220
	Starter Motor Servicing..................................................221
		Starter Motor Components.............................................221
		Before You Begin.....................................................222
		Starter Motor Removal................................................223
		Starter Motor Disassembly............................................223
		Inspection...........................................................225
			Armature.........................................................225
			Field Coil.......................................................227
		Brush Holder.........................................................228
			Magnetic Switch..................................................229
			Pinion Clutch Assembly...........................................230
		Starter Motor Assembly...............................................231
			Check Pinion Projection Length...................................232
		No Load Test.........................................................233
		Starter Motor Installation...........................................233
Alternator...................................................................234
	Alternator Service Information...........................................239
	Alternator Troubleshooting...............................................240
	Alternator Precautions...................................................241
	Alternator Components....................................................242
	Alternator Servicing.....................................................243
		Before You Begin Servicing...........................................243
		Removal of Alternator................................................244
		Disassembly of Alternator............................................245
		Inspection...........................................................248
			Stator Coil......................................................248
			Rotor............................................................248
			Rectifier........................................................249
			IC Regulator.....................................................250
			Diode............................................................252
			Brush............................................................252
		Assembly of Brush Holder.............................................253
		Assembly of Alternator...............................................255
		Installation of Alternator...........................................256
		Bench Test...........................................................257
			Test Wiring......................................................258
			Regulated Voltage Check..........................................259
			No Load Test.....................................................259
			Output Test......................................................259
Electric Wiring..............................................................260
	Electric Wiring Precautions..............................................262
	Electrical Wire Resistance...............................................263
	Battery Cable Resistance.................................................264
	Electrical Wire Sizes - Voltage Drop.....................................265
	Conversion of AWG to European Standards..................................266
	Electric Wiring Diagram (Reference)......................................267
Troubleshooting..............................................................268
	Special Service Tools....................................................270
	Troubleshooting By Measuring Compression Pressure........................271
		Compression Pressure Measurement Method..............................271
		Standard Compression Pressure........................................272
		Engine Speed and Compression Pressure (Use for Reference)............272
		Measured Value and Troubleshooting...................................273
	Quick Reference Table For Troubleshooting................................273
BACK COVER...................................................................279