Yanmar 4TNE92-NMH 4TNE92-NMHA 4TNE98-NMH Series Service Manual PDF

Yanmar 4TNE92-NMH 4TNE92-NMHA 4TNE98-NMH Series Service Manual – PDF DOWNLOAD

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Yanmar 4TNE92-NMH 4TNE92-NMHA 4TNE98-NMH Series Service Manual – PDF DOWNLOAD

Language : English
Pages : 281
Downloadable : Yes
File Type : PDF

UTILEV PN: 76000368

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Yanmar 4TNE92-NMH 4TNE92-NMHA 4TNE98-NMH Series Service Manual – PDF DOWNLOAD

Introduction 6
Yanmar Warranties 8
Yanmar Limited Warranty 10
What is Covered by this Warranty? 10
How Long is the Warranty Period? 10
What the Engine Owner Must Do: 10
To Locate an Authorized Yanmar Industrial Engine 10
Dealer or Distributor: 10
What Yanmar Will Do: 10
What is Not Covered by this Warranty? 11
Warranty Limitations: 11
Warranty Modifications: 11
Questions: 11
Customer Registration 11
Yanmar Co , Ltd Limited Emission Control 12
System Warranty – USA Only 12
Your Warranty Rights and Obligations: 12
California 12
Manufacturer’s Warranty Period: 12
Warranty Coverage: 13
Warranted Parts: 13
Exclusions: 14
Owner’s Warranty Responsibilities: 14
Safety 16
Safety Statements 16
Safety Precautions 17
Before You Operate 17
During Operation and Maintenance 17
General Service Information 30
Component Identification 32
Location of Labels 32
EPA / ARB Emission Control Regulations – USA Only 33
Emission Control Labels 33
EPA / ARB Labels 33
The 97/68/EC Directive Certified Engines 33
Engine Family 34
Function of Major Engine Components 35
Function of Cooling System Components 37
Diesel Fuel 38
Diesel Fuel Specifications 38
Additional Technical Fuel Requirements 38
Bio-Diesel Fuels 38
Filling The Fuel Tank 39
Priming the Fuel System 41
Engine Oil 43
Engine Oil Specifications 43
Service Categories 43
Definitions 43
Additional Technical Engine oil Requirements: 43
Engine Oil Viscosity 43
Checking Engine Oil 44
Adding Engine Oil 44
Engine Oil Capacity (Typical) 44
Engine Coolant 45
Engine Coolant Specifications 45
Alternative Engine Coolant 45
Additional Technical Coolant Specifications: 46
Filling Radiator With Engine Coolant 46
Engine Coolant Capacity (Typical) 47
Specifications 48
Description of Model Number 48
Engine Speed Specifications 48
Engine General Specifications 48
Principal Engine Specifications 49
4TNE92-NMH 49
4TNE92-NMHA 50
4TNE98-NMH 51
Engine Service Information 52
Engine Tuning 52
Tightening Torques for Standard Bolts and Nuts 53
Standard Torque Chart 54
Abbreviations and Symbols 55
Abbreviations 55
Symbols 55
Unit Conversions 56
Unit Prefixes 56
Prefix 56
Symbol 56
Power 56
Units of Length 56
Units of Volume 56
Units of Mass 56
Units of Force 56
Units of Torque 56
Units of Pressure 56
Units of Power 56
Units of Temperature 56
Periodic Maintenance 58
Precautions 73
The Importance of Periodic Maintenance 73
Performing Periodic Maintenance 73
Yanmar Replacement Parts 73
Required EPA / ARB Maintenance – USA Only 73
EPA / ARB Installation Requirements – USA Only 73
Tightening Fasteners 73
Standard Torque Chart 74
Periodic Maintenance Schedule 74
Periodic Maintenance Procedures 76
Daily 76
Drain Fuel Filter / Water Separator 76
Check Fuel Hoses and Engine Coolant Hoses 77
Every 250 Hours of Operation 78
Check and Clean Radiator Fins 78
Check and Adjust Cooling Fan V-belt 79
Check Battery 80
Clean Air Cleaner Element 81
Every 500 Hours of Operation 83
Replace Engine Oil and Engine Oil Filter 83
Check and Adjust the Governor Lever and Engine Speed Control 85
Every 1000 Hours of Operation 86
Adjust Intake / Exhaust Valve Clearance 86
Clean Fuel Filter / Water Separator 86
Replace Fuel Filter 88
Every 2000 Hours of Operation 91
Replace Air Cleaner Element 91
Inspect Clean and Test Fuel Injectors 91
Every 4000 Hours of Operation 92
Drain, Flush, and Re-fill the Coolant System with New Coolant 92
Replace Fuel Hoses and Engine Coolant Hoses 93
Engine 94
Engine Service Information 98
Engine Body 98
Cylinder Head 98
Intake / Exhaust Valve and Guide 98
Valve Spring 99
Rocker Arm and Shaft 99
Push Rod 99
Gear Train and Camshaft 100
Camshaft 100
Idler Gear Shaft and Bushing 100
Backlash of Each Gear 101
Cylinder Block 101
Crankshaft 101
Thrust Bearing 102
Piston 102
Piston Ring 103
Connecting Rod 103
Tappet 104
Engine Special Torque Chart 105
Special Service Tools 106
Measuring Instruments 108
Before You Begin Servicing 111
Removal of Engine 112
Cylinder Head Components 113
Disassembly of Cylinder Head 114
Removal of Glow Plugs 115
Removal of Valve Cover 115
Removal of Rocker Arm Assembly 115
Disassembly of Rocker Arm Assembly 116
Removal of Cylinder Head 116
Removal of Intake / Exhaust Valves 117
Removal of Valve Guides 117
Cleaning of Cylinder Head Components 118
Inspection of Cylinder Head Components 118
Inspection of Push Rods 118
Inspection of Rocker Arm Assembly 119
Inspection of Valve Guides 119
Inspection of Cylinder Head 119
Inspection of Intake and Exhaust Valves 119
Inspection of Valve Springs 121
Assembly of Cylinder Head 121
Assembly of Valve Guides 121
Assembly of Intake and Exhaust Valves 122
Assembly of Cylinder Head 123
Assembly of Rocker Arm Assembly 123
Assembly of the Valve Cover 124
Assembly of Glow Plugs 124
Measuring and Adjusting Valve Clearance 125
Valve Clearance Measurement 125
Valve Clearance Adjustment 126
Drive Train and Camshaft Components 127
Disassembly of Drive Train and Camshaft Components 128
Removal of Oil Pan 129
Removal of Oil Sump Pump 129
Removal of Timing Gears 129
Removal of Pistons 130
Removal of Crankshaft 131
Removal of Camshaft 132
Removal of Gear Case 133
Inspection of Drive Train and Camshaft Components 133
Inspection of Cylinder Block 133
Inspection of Pistons 137
Inspection of Piston Pin 137
Inspection of Connecting Rod 138
Inspection of Tappets 138
Inspection of Crankshaft 138
Inspection of Camshaft 139
Inspection of Camshaft Bushings 140
Inspection of Idler Gear and Shaft 140
Honing and Boring 141
Assembly of Drive Train and Camshaft Components 142
Assembly of Pistons 142
Installation of Gear Case 143
Installation of Crankshaft 143
Installation of Pistons 144
Installation of Camshaft 145
Installation of Timing Gears 145
Installation of Gear Case Cover 146
Installation of Oil Sump Pump 146
Installation of Oil Pan 146
Fuel System 148
Fuel System Special Torque Chart 150
Measuring Instruments 150
Fuel System Components 153
Fuel System Diagram 154
Structure and Operation of Fuel Injection Pump 156
Overview 157
Pump 157
Governor 157
Timer 158
Feed Pump (Vane Type) 158
Regulating Valve 159
Plunger Operation 160
Process 161
Suction Process 161
Injection Process 161
End of Injection 162
Uniform Pressure Process 162
Reverse Rotation Prevention Mechanism 163
Fuel Injection Volume Adjustment Mechanism 163
Delivery Valve Assembly 164
Delivery Valve Holder with Damping Valve 164
All -Speed Governor 165
At Start of Engine 167
During Idling 168
At Full-Load Maximum Speed Control 169
At No-Load Maximum Speed Control 170
Full-Load Position Adjustment Mechanism 171
Structure and Operation of Timer 172
Standard Type Automatic Timer 172
Magnetic Valve (Stop Solenoid) 173
Before You Begin Servicing 174
Removal of Fuel Injection Pump 175
Installation of the Fuel Injection Pump 178
Checking / Adjustment of Fuel Injection Timing 180
Servicing the Fuel Injectors 182
Removal of the Fuel Injectors 182
Inspection and Testing of the Fuel Injectors 183
Test Procedure Using a Nozzle Tester 183
Judgement Criteria on Atomization Condition 185
Cleaning of Nozzle 186
Installation of Fuel Injectors 186
Cooling System 188
Measuring Instruments 191
Cooling System Diagram 193
Model 4TNE92-NMHA 193
Models 4TNE92-NMH and 4TNE98-NMH 194
Engine Coolant Pump Components 195
Model 4TNE92-NMHA 195
Models 4TNE92-NMH and 4TNE98-NMH 196
Before You Begin Servicing 197
Engine Coolant System Check 198
Disassembly of Engine Coolant Pump 199
Disassembly of the 4TNE92-NMHA Coolant Pump 200
Disassembly of the 4TNE92-NMH and 4TNE98-NMH 200
Coolant Pumps 200
Cleaning and Inspection 201
Thermostat 201
Radiator Cap 201
Assembly of Engine Coolant Pump 202
Assembly of the 4TNE92-NMHA Coolant Pump 202
Assembly of the 4TNE92-NMH and 4TNE98-NMH 202
Coolant Pumps 202
Assembly of All Coolant Pump Models 203
Lubrication System 206
Oil Pump Service Information 210
Engine Oil Pressure – All Models 210
Outer Rotor Outside Clearance – All Models 210
Outer Rotor Side Clearance – All Models 210
Outer Rotor to Inner Rotor Tip Clearance – All Models 210
Rotor Shaft Clearance – All Models 210
Lubrication System Diagram 211
Checking Engine Oil Pressure 212
Oil Pump Components 212
Before You Begin Servicing 212
Disassembly of Oil Pump 214
Cleaning and Inspection 214
Check Outer Rotor Outside Clearance 215
Outer Rotor to Inner Rotor Tip Clearance 215
Check Outer Rotor Side Clearance 215
Check Rotor Shaft Clearance 215
Assembly of Oil Pump 216
Starter Motor 218
Starter Motor Service Information 222
Starter Motor Troubleshooting 223
Starter Motor Precautions 224
Starter Motor Servicing 225
Starter Motor Components 225
Before You Begin 226
Starter Motor Removal 227
Starter Motor Disassembly 227
Inspection 229
Armature 229
Field Coil 231
Brush Holder 232
Magnetic Switch 233
Pinion Clutch Assembly 234
Starter Motor Assembly 235
Check Pinion Projection Length 236
No Load Test 237
Starter Motor Installation 237
Alternator 238
Alternator Service Information 243
Alternator Troubleshooting 244
Alternator Precautions 245
Alternator Components 246
Alternator Servicing 247
Before You Begin Servicing 247
Removal of Alternator 248
Disassembly of Alternator 249
Inspection 252
Stator Coil 252
Rotor 252
Rectifier 253
IC Regulator 254
Diode 256
Brush 256
Assembly of Brush Holder 257
Assembly of Alternator 259
Installation of Alternator 260
Bench Test 261
Test Wiring 262
Regulated Voltage Check 263
No Load Test 263
Output Test 263
Electric Wiring 264
Electric Wiring Precautions 266
Electrical Wire Resistance 267
Battery Cable Resistance 268
Electrical Wire Sizes – Voltage Drop 269
Conversion of AWG to European Standards 270
Electric Wiring Diagram 271
Troubleshooting 272
Special Service Tools 274
Troubleshooting By Measuring Compression Pressure 275
Compression Pressure Measurement Method 275
Standard Compression Pressure 276
Engine Speed and Compression Pressure (Use for Reference) 276
Measured Value and Troubleshooting 277
Quick Reference Table For Troubleshooting 277
Service Manual Disclaimer pdf 0
The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the product Updated technical service information may be available from your local authorized UTILEV® distributor   Service Manuals provide general guidelines for maintenance and service and are intended for use by trained and experienced technicians Failure to properly maintain equipment or to follow instructions contained in the Service Manual could result in damage to the products, personal injury, property damage or death   2