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

1. GENERAL
1-6 How to read this manual
(1) Range of Operation Explanation
This manual explains the troubleshooting, installation/removal, replacement, disassembly/reassembly,
inspection, adjustment and adjusting operation procedures for the engine.
Refer to the manufacturer's manual for each
of the fuel injection pump, governor, starting motor and alterna-
tor except for their installation.
(2)
How to Read the Explanations
(2-1) An exploded view, sectional views, a system diagram, etc. are shown at the beginning of each section
as required for easy understanding
of the mounted states of the components.
(2-2) For the removal/installation of each part, the procedure is shown with the procedural step No.
in the
illustration.
(2-3) Precautions and key points for disassembly and reassembly
of parts are described as Points. In the
explanation for each point, detailed operation method, information, standard and precautions are
described.
Description Example
Illustration
HJZ06167
a The job contents are described in the disassembly procedure for Nos. not shown in the illustration.
Disassembly procedure
(1) Follow steps (1) to (12) of the cylinder head
disassembly procedure.
(2) Remove the cooling water pump.
(3) Remove the crankshaft pulley. (Point 1)
t
Operation Points
Disassemble: Service point for removal
Reassemble: Service point for installation
Disassemble-Reassemble : Service point
required in both removal and installation.
Operation point to be explained
on a later page.
1-12
4D92E,4D94LE,4D98E

1. GENERAL
Contents omitted in this manual
Though the following
jobs are omitted in the explanation in this manual, they shold be conducted in
actual work:
(1) Jacking up and lifting
(2) Cleaning and washing
of removed parts as required
(3) Visual inspection
(3)
Definition of Terms
k
Standard:
Instruction whose negligence is very likely to cause an accident. Always observe it.
Allowable range for inspection and adjustment.
Limit: The maximum or minimum value that must be satisfied during inspection or adjustment.
(4)
Abbreviations
Abbreviation Meaning
Ass'y assembly
Sub-Ass'y sub-assembly
AT D.C. after top dead center
B.TD.C. before top dead center
STD Standard
IN Intake
EX Exhaust
TD.C top dead center
B.D.C bottom dead center
as
oversize
US undersize
rpm revolutions per minute
HP output (horsepower)
3 Bolt/nut tightening torque
4D92E,4D94LE,4D98E
1-13

1. GENERAL
1-7 Precautions for service work
(1) Precautions for Safety
Read the safety precautions given at the beginning of this manual carefully and always mind safety in work.
(2)
Preparation for Service Work
Preparation is necessary for accurate, efficient service work. Check the customer ledger file for the history
of the engine.
(2-1) Preceding service date
(2-2) Period/operation hours after preceding service
(2-3) Problems and actions
in preceding service
(2-4) Replacement parts expected to be required for service
(2-5) Recording form/check sheet required for service
(3)
Preparation before Disassembly
(3-1) Prepare general tools, special service tools, measuring instruments, oil, grease, non-reusable parts,
and parts expected to be required for replacement.
(3-2) When disassembling complicated portions, put matchmarks and other marks at places not adversely
affecting the function for easy reassembly.
(4)
Precautions in Disassembly
(4-1) Each time a parts is removed, check the part installed state, deformation, damage, roughening,
surface defect, etc.
(4-2) Arrange the removed parts orderly with clear distinction between those to be replaced and those to be
used again.
(4-3) Parts to be used again shall be washed and cleaned sufficiently.
(4-4) Select especially clean locations and use clean tools for disassembly
of hydraulic units such as the
fuel injection pump.
(5)
Precautions for Inspection and Measurement
(5-1) Inspect and measure parts to be used again as required to determine whether they are reusable or
not.
(6)
Precautions for Reassembly
(6-1) Reassemble correct parts in correct order according to the specified standards (tightening torques,
and adjustment standards). Apply oil to important bolts and nuts before tightening when specified.
(6-2) Always use genuine parts for replacement.
(6-3) Always use new oil seals, O-rings, packings and cotter pins.
(6-4) Apply sealant to packings depending on the place where they are used. Apply oil or grease to sliding
contact portions, and apply grease to oil seal lips.
(7)
Precautions for Adjustment and Check
(7-1) Use measuring instruments for adjustment to the specified service standards.
1-14
4D92E,4D94LE,4D98E

1. GENERAL
1-8 Tightening torques for standard bolts and nuts
(Lubricating oil not applied) (Unit: Nm {kgfom})
Item Nominal thread Tightening torque Remarks
diameter x pitch
M6 x 1 9.8
-11 .8 {1.0 -1 .2} 1)Use 80% of the value at left when
M8 x 1.25 22.5 - 28.4 {2.3 - 2.9} the tightening side is aluminum.
2)Use 60%
of the value at left for 4T
Hexagon bolt
(IT)/nut
bolts and lock nuts.
M10 x 1.5 44.1 - 53.9 {4.5 - 5.5}
M12x1.75
78.4 -98 {8.0 - 10}
1/8 9.8
{1 .0}
1/4 19.6 {2.0}
PT plug 3/8 29.4 {3.0}
1/2 58.8 {6.0}
M8 12.7 -16.7 {1.3 -1.7}
M12 24.5 - 34.3 {2.5 - 3.
5}
Pipe joint bolt M14 39.2 - 49 {4.0 - 5.0}
M16 49 -58.8 {5.0 - 6.0}
4D92E,4D94LE,4D98E
1-15