PDF Service Manual UTILEV Yanmar 4TNE92 4TNE98 Engine - 2 MB
This service manual provides detailed repair and maintenance information for the Yanmar 4TNE92 and 4TNE98 series engines used in UTILEV equipment.
It covers all procedures from simple adjustments to complete engine overhauls.
This is an essential guide for technicians servicing these reliable diesel engines.
PDF Viewer
Viewer loads when you scroll here
SHARE THIS MANUAL
Download the PDF Manual
PDF viewer loading area
Text Preview from This Manual
The text below was extracted from the visible preview pages to help you confirm the manual contents before download.
--- Page 1 ---
TNE series
SERVICE MANUAL
4TNE92-NMH • 4TNE92-NMHA
4TNE98-NMH
TNE Service Manual
P/N: 0B2991-U0001
INDUSTRIAL
ENGINES
UTILEV PN: 76000368
--- Page 3 ---
YANMAR WARRANTIES
Yanmar Limited Warranty - Continued
What is Not Covered by this Warranty?
This Warranty does not cover parts affected by or damaged by, but not limited to, accident, misuse, abuse,
“Acts of God,” neglect, improper installation, improper maintenance, improper storage, the use of unsuitable
attachments or parts, the use of contaminated fuels, the use of fuels, oils, lubricants, or fluids other than
those recommended in your Yanmar Operation Manual, unauthorized alterations or modifications, ordinary
wear and tear, and rust or corrosion. This Warranty does not cover the cost of parts and / or labor required to
perform normal / scheduled maintenance on your Yanmar engine. This Warranty does not cover consumable
parts such as, but not limited to filters, belts, hoses, fuel injector nozzles, lubricants and cleaning fluids.
Warranty Limitations:
The foregoing is Yanmar's only obligation to you and your exclusive remedy for breach of warranty.
Failure to follow the requirements for submitting a claim under this Warranty may result in a waiver of all
claims for damages and other relief. In no event shall Yanmar or any authorized industrial engine dealer
or distributor be liable for incidental, special or consequential damages. Such consequential damages
may include, but not be limited to, loss of revenue, loan payments, cost of rental of substitute equipment,
insurance coverage, storage, lodging, transportation, fuel, mileage and telephone costs. The limitations in
this Warranty apply regardless of whether your claims are based on breach of contract, tort (including
negligence and strict liability) or any other theory. Any action arising hereunder must be brought within one
(1) year after the cause of action accrues or it shall be barred. Some states and countries do not allow
certain limitations on warranties or for breach of warranties. This Warranty gives you specific legal rights,
and you may also have other rights which vary from state to state and country to country. Limitations
set forth in this paragraph shall not apply to the extent that they are prohibited by law.
Warranty Modifications:
Except as modified in writing and signed by the parties, this Warranty is and shall remain the complete and
exclusive agreement between the parties with respect to warranties, superseding all prior agreements,
written and oral, and all other communications between the parties relating to warranties. No person or
entity is authorized to give any other warranty or to assume any other obligation on behalf of
Yanmar, either orally or in writing.
Questions:
If you have any questions or concerns regarding this Warranty, please call or write to the nearest authorized
Yanmar industrial engine dealer or distributor or other authorized facility.
Customer Registration
Customer registration is very important for the original retail purchaser to enable Yanmar to provide
the best support for your engine.
At the time of purchase, Yanmar highly recommends registering the customer’s information through website
http://www.yanmar.co.jp as soon as possible.
If it is not possible to access the website, please contact the nearest authorized Yanmar industrial engine
dealer or distributor.
2-4 TNE Service Manual
--- Page 4 ---
SAFETY
A WARNING A WARNING
SEVER HAZARD! EXHAUST HAZARD!
• Keep hands and other body parts • NEVER operate the engine in an
away from moving / rotating parts enclosed area such as a garage,
such as the cooling fan, flywheel or tunnel, underground room, manhole or
PTO shaft. ship’s hold without proper ventilation.
• Wear tight fitting clothing and keep • NEVER block windows, vents, or other
your hair short or tie it back while the means of ventilation if the engine is
engine is running. operating in an enclosed area. All
• Remove all jewelry before you operate internal combustion engines create
or service the machine. carbon monoxide gas during
operation. Accumulation of this gas
• NEVER start the engine in gear. within an enclosure could cause
Sudden movement of the engine illness or even death.
and / or machine could cause death or
serious personal injury. • Make sure that all connections are
tightened to specifications after repair
• NEVER operate the engine without the is made to the exhaust system.
guards in place.
• Failure to comply could result in death
• Before you start the engine make sure or serious injury.
that all bystanders are clear of the 0000003en
area.
• Keep children and pets away while the
engine is operating.
A WARNING
• Check before starting the engine that
any tools or shop rags used during
maintenance have been removed from
the area.
• Failure to comply could result in death
ALCOHOL AND DRUG HAZARD!
or serious injury.
0000002en
• NEVER operate the engine while you
are under the influence of alcohol or
drugs.
• NEVER operate the engine when you
are feeling ill.
• Failure to comply could result in death
or serious injury.
0000004en
3-6 TNE Service Manual
--- Page 5 ---
GENERAL SERVICE INFORMATION
Engine Speed Specifications................................................... 4-19
Engine General Specifications ................................................ 4-19
Principal Engine Specifications ..................................................... 4-20
4TNE92-NMH.......................................................................... 4-20
4TNE92-NMHA ....................................................................... 4-21
4TNE98-NMH.......................................................................... 4-22
Engine Service Information ........................................................... 4-23
Engine Tuning ......................................................................... 4-23
Tightening Torques for Standard Bolts and Nuts .......................... 4-24
Standard Torque Chart.................................................................. 4-25
Abbreviations and Symbols........................................................... 4-26
Abbreviations........................................................................... 4-26
Symbols................................................................................... 4-26
Unit Conversions ........................................................................... 4-27
Unit Prefixes ............................................................................ 4-27
Units of Length ........................................................................ 4-27
Units of Volume ....................................................................... 4-27
Units of Mass........................................................................... 4-27
Units of Force .......................................................................... 4-27
Units of Torque........................................................................ 4-27
Units of Pressure..................................................................... 4-27
Units of Power ......................................................................... 4-27
Units of Temperature............................................................... 4-27
4-2 TNE Service Manual
--- Page 6 ---
GENERAL SERVICE INFORMATION
3. Observe the fuel level sight gauge Priming the Fuel System
(Figure 4-2, (3)) and stop fueling when gauge
shows fuel tank is full. NEVER overfill the fuel
tank.
A DANGER
4. Replace the fuel cap (Figure 4-2, (1)) and hand
tighten. Over-tightening the fuel cap will
damage it.
(1)
FIRE AND EXPLOSION HAZARD!
• Diesel fuel is extremely flammable and
explosive under certain conditions.
(2) • Place an approved container under the
air bleed port when you prime the fuel
system. Never use a shop rag to catch
the fuel. Wipe up any spills
(3) immediately. ALWAYS close the air
bleed port after you complete priming
the system.
0000002A
• Wear eye protection. The fuel system
Figure 4-3 is under pressure and fuel could spray
out when you open the air bleed port.
• If the unit has an electric fuel pump,
turn the key switch to the ON position
for 10 to 15 seconds, or until the fuel
coming out of the air bleed port is free
of bubbles, to allow the electric fuel
pump to prime the system.
• If the unit has a mechanical fuel pump,
operate the fuel priming pump several
times until the fuel coming out of the
air bleed port is free of bubbles.
• Failure to comply will result in death or
serious injury.
0000006en
4-12 TNE Service Manual
--- Page 7 ---
GENERAL SERVICE INFORMATION
4TNE98-NMH
Engine Model 4TNE98-NMH
Version VM
Type Vertical Inline Diesel Engine
Combustion System Indirect Injection
Aspiration Natural
No. of Cylinders 4
Bore × Stroke 3.86 x 4.33 in (98 × 110 mm)
Displacement 202.5 cu in (3.319 L)
Max. Rated Output (Net) rpm
2400
(min-1)
hp SAE 63.6
kW 47.4
PS
High Idle Speed 2725 ± 25 64.4
(Bare Engine) rpm
Low Idle Speed
850 ± 25 rpm
(Bare Engine)
Engine Weight (Dry)* 491.6 lb (194 kg)
PTO Position Flywheel Side
Direction of Rotation Counterclockwise Viewed From Flywheel Side
Cooling System Liquid-Cooled With Radiator
Lubricating System Forced Lubrication With Trochoid Pump
At normal operating speeds, oil pressure is: 42 - 57 psi (0.29 - 0.39 MPa; 3.0 - 4.0 kgf/cm2)
At idle, oil pressure is: No less than 8.5 psi (0.06 MPa; 0.6 kgf/cm2)
Starting System Electric Starting - Starter Motor: DC12V, 3.1 hp (2.3 kW)
Alternator: DC12V, 60A
Recommended Battery Capacity: 12V, 622 CCA (Cold Cranking Amps)
Dimensions (L × W × H)* 24.9 x 19.6 x 28.0 in
(632 x 498 x 711 mm)
Engine Oil Pan Capacity 9.7 / 7.6 qt (9.2 / 7.2 L)
(Dipstick Upper Limit / Lower Limit)
Engine Coolant Capacity 1.11 gal (4.2 L) Engine Only
* Engine Specifications Without Cooling Fan,
Radiator, Muffler, and Air Cleaner.
4-22 TNE Service Manual
--- Page 8 ---
PERIODIC MAINTENANCE
A DANGER A DANGER
FIRE AND EXPLOSION HAZARD!
SCALD HAZARD! • Diesel fuel is extremely flammable and
• NEVER remove the radiator cap if the explosive under certain conditions.
engine is hot. Steam and hot engine • Only fill fuel tank with diesel fuel.
coolant will spurt out and seriously Filling fuel tank with gasoline may
burn you. Allow the engine to cool result in a fire.
down before you attempt to remove
the radiator cap. • NEVER refuel with engine running.
• Securely tighten the radiator cap after • Wipe up all spills immediately.
you check the radiator. Steam can • Keep sparks, open flames or any other
spurt out during engine operation if form of ignition (match, cigarette,
the cap is loose. static electric source) away when
• ALWAYS check the level of engine fueling / refueling.
coolant by observing the reserve tank. • NEVER overfill the fuel tank.
• Failure to comply will result in death or • Fill fuel tank and store fuel in a
serious injury. well-ventilated area only.
0000002en • Failure to comply will result in death or
serious injury.
0000005en
5-4 TNE Service Manual
--- Page 9 ---
PERIODIC MAINTENANCE
CAUTION CAUTION
NEVER use high pressure water or
compressed air at greater than 28 psi or
a wire brush to clean the radiator fins.
Radiator fins damage easily.
0000016en
Be environmentally responsible. Follow
these procedures for hazardous waste CAUTION
disposal. Failure to follow these
procedures may seriously harm the NEVER attempt to adjust the low or high
environment. idle speed limit screw. This may impair
the safety and performance of the
• Follow the guidelines of the EPA or machine and shorten its life. If the idle
other governmental agency for the speed limit screws require adjustment,
proper disposal of hazardous see your authorized Yanmar industrial
materials such as engine oil, diesel engine dealer or distributor.
fuel and engine coolant. Consult the 0000017en
local authorities or reclamation facility.
• NEVER dispose of hazardous CAUTION
materials irresponsibly by dumping
them into a sewer, on the ground or If the fuel filter / water separator is
into ground water or waterways. positioned higher than the fuel level in
0000013en
the fuel tank, water may not drip out
when the fuel filter / water separator
drain cock is opened. If this happens,
CAUTION turn the air vent screw on the top of the
Protect the air cleaner, turbocharger (if fuel filter / water separator 2-3 turns
equipped) and electric components counterclockwise.
from damage when you use steam or Be sure to tighten the air vent screw
use high-pressure water to clean the after the water has drained out.
engine. 0000025en
0000014en
CAUTION
CAUTION
• When the engine is operated in dusty
• NEVER overfill the engine with engine conditions, clean the air cleaner
oil. element more frequently.
• ALWAYS keep the oil level between • NEVER operate the engine with the air
upper and lower lines on the dipstick. cleaner or element(s) removed. This
0000015en may cause foreign material to enter the
engine and damage it.
0000026en
5-14 TNE Service Manual
--- Page 10 ---
PERIODIC MAINTENANCE
Clean Air Cleaner Element
(3) Note that a typical air cleaner is shown in
Figure 5-7 and Figure 5-8 for illustrative purposes
(2)
only.
The engine performance is adversely affected
(1) when the air cleaner element is clogged with dust.
Be sure to clean the air filter element periodically.
1. Unlatch and remove the air cleaner cover
(Figure 5-7, (1)).
0000067A
2. Remove the element (Figure 5-7, (2)) (outer
Figure 5-6 element if equipped with two elements).
• When the amount of fluid nears the lower limit
(Figure 5-6, (1)), fill with distilled water A CAUTION
(Figure 5-6, (2)) so it is at the upper limit
(Figure 5-6, (3)). If operation continues with
insufficient battery fluid, the battery life is
shortened, and the battery may overheat and
explode. During the summer, check the fluid
level more often than specified.
• If the engine cranking speed is so slow that the FLYING OBJECT HAZARD!
engine does not start, recharge the battery. • ALWAYS wear eye protection when
• If the engine still will not start after charging, servicing engine and when using
have your authorized Yanmar industrial engine compressed air or high-pressure
dealer or distributor check the battery and the water. Dust, flying debris, compressed
engine’s starting system. air, pressurized water or steam may
• If operating the machine where the ambient injure your eyes.
temperature could drop to 5°F (-15°C) or less, • Failure to comply may result in minor
remove the battery from the machine at the end or moderate injury.
of the day. Store the battery in a warm place 0000003en
until the next use. This will help start the engine
easily at low ambient temperatures.
5-24 TNE Service Manual
--- Page 11 ---
PERIODIC MAINTENANCE
Inspect Clean and Test Fuel Injectors
=
Every 2000 Hours of Operation
A WARNING
Perform the following maintenance every 2000
hours of operation.
• Replace Air Cleaner Element
• Inspect Clean and Test Fuel Injectors
HIGH PRESSURE HAZARD!
Replace Air Cleaner Element • Avoid skin contact with high pressure
diesel fuel spray caused by a fuel
CAUTION system leak such as a broken fuel
The maximum air intake restriction shall injection line. High pressure fuel can
be 0.90 psi (6.23 kPa; 635 mm Aq) or penetrate your skin and result in
less. Clean or replace the air cleaner serious injury. If you are exposed to
element if the air intake restriction high pressure fuel spray obtain
exceeds the above mentioned value. prompt medical treatment.
0000046en • NEVER check for a fuel leak with your
hands. ALWAYS use a piece of wood
or cardboard. Have your authorized
Replace the air cleaner element (Figure 5-7, (2)) Yanmar industrial engine dealer or
every 2000 hours even if it is not damaged or dirty. distributor repair the damage.
When replacing the element, clean the inside of the • Failure to comply could result in death
air cleaner case (Figure 5-7, (4)). or serious injury.
0000008en
If the air cleaner is equipped with a double element,
only remove and replace the inner element Proper operation of the fuel injectors is required to
(Figure 5-8, (1)) if the engine lacks power or the obtain the optimum injection pattern for full engine
dust indicator actuates (if equipped). This is in performance. The EPA / ARB requires that you
addition to replacing the outer element. have the injectors inspected, cleaned and tested
every 2000 hours. See Servicing the Fuel
Injectors on page 7-35.
5-34 TNE Service Manual
--- Page 12 ---
ENGINE
Backlash of Each Gear
Reference
Inspection Item Standard Limit
Page
Crankshaft Gear, Camshaft Gear, Idler Gear, Fuel Injection 0.0031 - 0.0055 in 0.0063 in
-
Pump Gear (0.08 - 0.14 mm) (0.16 mm)
0.0035 - 0.0059 in 0.0067 in
Lubricating Oil Pump Gear -
(0.09 - 0.15 mm) (0.17 mm)
Cylinder Block
Reference
Inspection Item Standard Limit
Page
3.6220 - 3.6232 in 3.6272 in
4TNE92
(92.000 - 92.030 mm) (92.130 mm)
3.7008 - 3.7020 in 3.7059 in See
Cylinder Inside Diameter 4TNE94 Inspection of
(94.000 - 94.030 mm) (94.130 mm)
Cylinder
3.8583 - 3.8594 in 3.8634 in
4TNE98 Block on
(98.000 - 98.030 mm) (98.130 mm)
page 6-40
Roundness 0.0004 in (0.01 mm) 0.0012 in
Cylinder Bore
Inclination or less (0.03 mm)
Crankshaft
Reference
Inspection Item Standard Limit
Page
0.0008 in
Bending (1/2 the dial gauge reading) -
(0.02 mm)
2.2816 - 2.2820 in 2.2796 in
Pin Outside Diameter
(57.952 - 57.962 mm) (57.902 mm)
Bearing Halves Inside 2.2835 - 2.2845 in
-
Diameter (58.000 - 58.026 mm)
Connecting Rod Journals
Bearing Halves 0.0587 - 0.0591 in
-
Thickness (1.492 - 1.500 mm) See
0.0015 - 0.0029 in 0.0059 in Inspection of
Oil Clearance
(0.038 - 0.074 mm) (0.150 mm) Crankshaft
Journal Outside 2.5572 - 2.5576 in 2.5552 in on page 6-45
Diameter (64.952 - 64.962 mm) (64.902 mm)
Bearing Halves Inside 2.5591 - 2.5598 in
-
Diameter (65.000 - 65.020 mm)
Crank Journal Selective Pairing
Bearing Halves 0.0785 - 0.0791 in
-
Thickness (1.995 - 2.010 mm)
0.0015 - 0.0027 in 0.0059 in
Oil Clearance
(0.038 - 0.068 mm) (0.150 mm)
6-8 TNE Service Manual
--- Page 13 ---
ENGINE
Before You Begin Servicing
A CAUTION
A WARNING
SEVER HAZARD! FLYING OBJECT HAZARD!
• Stop the engine before you begin to • ALWAYS wear eye protection when
service it. servicing engine and when using
compressed air or high-pressure
• NEVER leave the key in the key switch
water. Dust, flying debris, compressed
when you are servicing the engine.
air, pressurized water or steam may
Someone may accidentally start the
injure your eyes.
engine and not realize you are
servicing it. This could result in a • Failure to comply may result in minor
serious injury. or moderate injury.
0000003en
• If you must service the engine while it
is operating, remove all jewelry, tie
back long hair, and keep your hands, CAUTION
other body parts and clothing away • Only use the engine oil specified.
from moving / rotating parts. Other engine oils may affect warranty
• Failure to comply could result in death coverage, cause internal engine
or serious injury. components to seize, or shorten
0000010en engine life.
• Prevent dirt and debris from
A WARNING contaminating engine oil. Carefully
clean the oil cap / dipstick and the