Yanmar 4D92E User manual

SERVICE MANUAL
REVISED: FEBRUARY 2009
Read and observe all warnings on this unit
before operating it.
DO NOT operate this equipment unless all
factory installed guards and shields are
properly secured in place.
WARNING
4D94(L)E / 4D98E DIESEL ENGINES
Federal Environmental Protection Agency (EPA) Emission Control Compliant
BX20 S/N 580001A~ 4D94(L)E EPA TIER 2 400/500/600PD-14
BX50 S/N 200001A - 215882A 4D94(L)E EPA TIER 2 400/500/550/600/650/700PD-16
BX50 S/N 215883A~ 4D98E EPA TIER 3
SM197T
4D94E-BE4
4D94(L)E
4D98E

1. GENERAL
1-1 Specifications
Engine name -4D92E 4D94LE 4D98E
Engine specification class -For standard forklift truck
Type -Vertical, in-line, 4-cycle, water-cooled diesel engine
Combustion chamber -Swirl chamber type
Number
of cylinders -4
Cylinder bore x stroke
mmxmm 92 x 100 94 x
110 98 x 110
Displacement I 2.659 3.053 3.318
Revolving speed rpm 2,450 2,450 2,400
Rated output Output kW {HP} 33.8 {45.3} 44.1 {59.1} 48.9 {65'?}
Fuel injection timing
(ATD .C.) deg 4 6
Fuel injection pressure MPa 12.
3-13 .3
{kgf/cm'} {125
-135}
Ignition order -
1-3-4-2 (No.1 cylinder on flywheel side)
Power take off -Flywheel
Direction
of rotation -Counterclockwise (viewed from flywheel)
Cooling system -Radiator
Lubrication system -Forced lubrication with trochoid pump
Starting system -Electric
Applicable fuel -Diesel oil-ISO 8217 DMA,
BS 2869 A1 or A2
(cetane No. 45 min.)
Applicable lubricant -API grade class
CC or higher
Battery capacity V-AH
12-64 (5HR) or above
Lubricant capacity
Total I 7.5
(oil pan) Effective I 2
Cooling water capacity (engine only) I 4.2
Overall length
mm
700 (fan -flywheel)
Engine dimensions Overall width
mm
508 (fuel filter -alternator)
Overall height
mm 706 (oil pan -rocker cover upper surface)
Dry engine weight
kg 225
1-2 4D92E,4D94LE,4D98E

1. GENERAL
1-2 Fuel oil, lubricating oil and cooling water
Use proper fuel oil, lubricating oil and cooling water and change them according the Operation and Mainte-
nance Manual.
4D92E,4D94LE,4D98E 1-3

1. GENERAL
1-3 Engine performance curve
4D92E [Applicable machine: FD10/15/18-20]
Rated horsepower: 33.8 kW {45.3 HP}/2,450 rpm (Net)
Maximum torque: 147 Nm {15 kgfom}/1,600
rpm (Net)
Torque
!
147Nm{15kg!. mJ/160orpmj
0..
;;:
rfJ
:I:
-""
0..
100 100
70
90 90
80
60
80
70 70
50
60 60
33 . 8kW{45 . 4H~/2450rpm
=>
40
"-
50 50
'\.
=>
0
40
30
40
30 30
20
---
l..---
\
----
\~
\)~
/
.....-
/
--...
~
~
1\
I \
20 20
10
10 10
/
consump~J
\
Fuel
\
800 1.000 1.200 1.400 1.600 1.800 2,000 2,200 2,400 2,600
Engine speed(rpm)
E
'"
E
-"" z
60
600
50
500
40
400
Q)
=>
0-
30
300 0
I-
20
200
10 100
0 0
rfJ 3:
0..
0..
-""
:I:
" " "
'" '" '"
c
0
290
210 210
"-
E
280
=>
C/)
200 c
270 200 0
u
190
260
190
Q)
=>
250
LL
180
HJZ06160
1-4
4D92E,4D94LE,4D98E

4D94LE [Applicable machine: FD20/25/30-16, FD20N/25N/30N-16]
Rated horsepower: 44.1 kW {59.1 HP}/2,450 rpm (Net)
Maximum torque: 178.5
Nm {18.2 kgfom}/1 ,500 rpm (Net)
178. 5Nm{18. 2kgf. m}/1500rpm \
Torque
0..
3::
en
:I:
-'"'
0..
100 100
70
90 90
80
60
80
70 70
50
44kW{59HP}/2450rpm
-.....
60 60
"""-!I..
::J
40
0. 50 50
::J
0
40
30
40
30 30
20
20 20
10
10 10
0 0 0
/ V
'\
V
\J~
./
V
V V
/'" /
..-
l-/
Fuel
consumpt i ~
~
'---..
-r
~
1\
\
\
800 1.000 1.200 1.400 1.600 1.800 2.000 2.200 2.400 2.600
Engine speed (rpm)
4D92E,4D94LE,4D98E
1. GENERAL
E
'"
E
-'"' z
60
600
50
500
40
400
OJ
::J
0-
0
30
300
I-
20
200
10 100
en
'"
0..
0..
-'"'
:I:
"'- "'- "'-
'" '" '"
c
0
290
210 210
0.
E
280
::J
rn
200 c
270 200 0
0
190
260
190
OJ
::J
250
LL
180
HJZ06161
1-5

1. GENERAL
4D98E [Applicable machine: FD20H/25H/30H/35A-16]
Rated horsepower: 48.9 kW {65.7 HP}/2,400 rpm (Net)
Maximum torque: 215.7 Nm {22 kgfom}/1,700
rpm (Net)
215.7Nm{22kgf. ml/1700rpm \
I \
'Torque
"-
3<
(f)
:I:
"-
100 100
70
90 90
80
60
80
48. 9kW{65. 7H~/2400rpm
70 70
50
60 60
'"
40
0. 50 50
/
~
Y
0/
'"
0
40
30
40
30 30
/
/ /
20
/
20 20
\,
10
10 10
"""-
Fuel
consumpt i ~
.......
E
'"
E
-'"
z
60
600
50
500
40
400
OJ
'"
c-
o
30
300
f-
--
1'\
20
200
10 100
0 0
'\
\
(f)
3:
"-
"-
-'"
:I:
1\
"- "- "-
'" '" '"
1\
/ \
~
\
\
c
0
290
210 210
0.
E
280
'"
00
200 200
c
270
0
u
190
260
190
OJ
'"
250
LL
180
800 1.000 1.200 1.400 1.600 1.800 2.000 2.200 2.400 2.600
Engine speed (rPm)
HJZ06162
1-6
4D92E,4D94LE,4D98E

1. GENERAL
1-4 Engine external views
4D92E194LE/98E
11 10
HJZ06163
1) Starting motor 7) Fuel injection pump
2) Exhaust manifold 8) Oil pan
3) Alternator 9) Oil filter
4) Radiator fan 10) Flywheel housing
5) Intake manifold 11) Flywheel
6) Fuel filter
1-8
4D92E,4D94LE,4D98E

1. GENERAL
HJZ06164
12) Crankshaft pulley
4D92E,4D94LE,4D98E 1-9

1. GENERAL
1-5 Structural description
4D92E/94LE/98E
4
15
10
14
13 12 II HJZ06165
1) Exhaust manifold 9) Tappet
2) Fuel injection nozzle 10) Camshaft
3) Preheater coil 11) Engine oil pan
4) Rocker arm housing 12) Oil strainer
5) Rocker arm 13) Connecting rod cap bolt
6) Intake manifold 14) Engine oil filter (oil cooler: option)
7) Piston 15) Fuel injection pump
8) Cylinder block
1-10
4D92E,4D94LE,4D98E

1. GENERAL
16 11 18 19
20
23
21
22
HJZ06166
16) Water pump 20) Flywheel housing
17) Thermostat 21) Crankshaft
18) Cylinder head gasket 22) Gear case (equipped with oil pump)
19) Cylinder head 23) Gear
4D92E,4D94LE,4D98E
1-11