Yanmar 4TNE92-NMH, 4TNE92-NMHA, 4TNE98-NMH Service Manual
TNE
UTILEV PN: 76000368
SERVICE MANUAL
4TNE92-NMH • 4TNE92-NMHA
4TNE98-NMH
TNE Service Manual
P/N: 0B2991-U0001
series
INDUSTRIAL
ENGINES
English Language Manual Available
If you would like a copy of this manual in the English language, please contact your local authorized Yanmar
industrial engine dealer or distributor. A list of authorized Yanmar industrial engine dealers and distributors
can be found at http://www.yanmar.co.jp/english/index-network.htm. Note that authorized Yanmar
industrial engine dealers and distributors are indicated as “Land” under the “Sales Network” menu.
Disclaimers:
We reserve the right to change specifications and to improve our products without notice or obligation.
Yanmar and are registered trademarks of Yanmar Co., Ltd. in Japan, the United States and / or
other countries.
All Rights Reserved:
No part of this publication may be reproduced or used in any form by any means - graphic, electronic, or
mechanical, including photocopying, recording, taping, or information storage and retrieval systems - without
the written permission of Yanmar Co., Ltd.
© 2005 Yanmar Co. Ltd.
ii TNE Service Manual
TABLE OF
CONTENTS
TNE Service Manual
Introduction ............................................................................................ 1-1
Yanmar Warranties ............................................................................... 2-1
Safety .................................................................................................... 3-1
General Service Information .................................................................. 4-1
Periodic Maintenance ............................................................................ 5-1
Engine ................................................................................................... 6-1
Fuel System .......................................................................................... 7-1
Cooling System ..................................................................................... 8-1
Lubrication System ................................................................................ 9-1
Starter Motor ....................................................................................... 10-1
Alternator ............................................................................................. 11-1
Electric Wiring ..................................................................................... 12-1
Troubleshooting ................................................................................... 13-1
TNE Service Manual
iii
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iv TNE Service Manual
Section 1
INTRODUCTION
TNE Service Manual
This manual describes the service procedures for
the TNE series indirect injection engines. These
engines are certified by the U.S. EPA, California
ARB and/or the 97/68/EC Directive for industrial
use.
Please use this manual for accurate, quick and safe
servicing of the engine. Since the directions in this
manual are for a typical engine, some
specifications and components may be different
from your engine. Refer to the documentation
supplied by the optional equipment manufacturer
for specific service instructions.
Yanmar products are continuously undergoing
improvement. This Service Manual might not
address possible field modifications to the
equipment. Contact an authorized Yanmar
industrial engine dealer or distributor for answers to
any questions relating to field modifications.
TNE Service Manual
1-1
INTRODUCTION
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1-2 TNE Service Manual
WARRANTIES
TNE Service Manual
Yanmar Limited Warranty................................................................ 2-3
What is Covered by this Warranty?........................................... 2-3
How Long is the Warranty Period?............................................ 2-3
What the Engine Owner Must Do:............................................. 2-3
To Locate an Authorized Yanmar Industrial Engine
Dealer or Distributor: ................................................................. 2-3
What Yanmar Will Do: ............................................................... 2-3
What is Not Covered by this Warranty? .................................... 2-4
Warranty Limitations:................................................................. 2-4
Warranty Modifications:............................................................. 2-4
Questions: ................................................................................. 2-4
Customer Registration............................................................... 2-4
Section 2
YANMAR
Table of Contents
Page
Yanmar Co., Ltd. Limited Emission Control
System Warranty - USA Only.......................................................... 2-5
Your Warranty Rights and Obligations: ..................................... 2-5
Manufacturer’s Warranty Period:............................................... 2-5
Warranty Coverage: .................................................................. 2-6
Warranted Parts: ....................................................................... 2-6
Exclusions: ................................................................................ 2-7
Owner’s Warranty Responsibilities:........................................... 2-7
TNE Service Manual
2-1
YANMAR WARRANTIES
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2-2 TNE Service Manual
YANMAR WARRANTIES
YANMAR LIMITED WARRANTY
What is Covered by this Warranty?
Yanmar warrants to the original retail purchaser that your new Yanmar TNE Series Industrial Engine will be
free from defects in material and / or workmanship for the duration of the warranty period.
How Long is the Warranty Period?
The Yanmar standard limited warranty period begins on the date of the delivery of the new Yanmar TNE
Series Industrial Engine to the first retail purchaser and extends for a period of twenty-four (24) months or
two-thousand (2000) engine operation hours, whichever occurs first.
What the Engine Owner Must Do:
If you believe your Yanmar engine has experienced a failure due to a defect in material and / or
workmanship, you must contact an authorized Yanmar industrial engine dealer or distributor within thirty (30)
days of discovering the failure. You must provide proof of ownership of the engine, proof of the date of the
engine purchase and delivery, and documentation of the engine operation hours. You are responsible for the
transportation of the engine to and from the repair location as designated by Yanmar.
Yanmar strongly recommends you register your engine as soon as possible after purchase in order to
facilitate any future warranty matters.
To Locate an Authorized Yanmar Industrial Engine Dealer or Distributor:
You can locate your nearest authorized Yanmar industrial engine dealer or distributor by visiting the Yanmar
Corp., Ltd. web site at:
http://www.yanmar.co.jp
• The Japanese language page will be displayed. For English language “click” on “English Page.”
• “Click” on “Network” in the web site heading to view the “Yanmar Worldwide Network.”
• Choose and “Click” on the desired product group.
• “Click” on the Icon closest to your region.
• “Click” on the disired country or Associate company to locate your nearest authorized Yanmar industrial
engine dealer or distributor.
• You may also contact Yanmar by clicking on “Inquiry” in the web site heading.
What Yanmar Will Do:
Yanmar warrants to the original retail purchaser of a new Yanmar engine that Yanmar will make such repairs
and / or replacements necessary to correct any defects in materials and / or workmanship discovered during
the warranty period. Such repairs and / or replacements will be made at a location designated by Yanmar.
TNE Service Manual
2-3
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
If it is not possible to access the website, please contact the nearest authorized Yanmar industrial engine
dealer or distributor.
as soon as possible.
2-4 TNE Service Manual
YANMAR WARRANTIES
YANMAR CO., LTD. LIMITED EMISSION CONTROL SYSTEM
WARRANTY - USA ONLY
Your Warranty Rights and Obligations:
California
The California Air Resources Board (CARB) then Environmental Protection Agency (EPA) and Yanmar Co.,
Ltd. hereafter referred to as Yanmar, are pleased to explain the emission control system warranty on your
industrial compression-ignition engine. In California, model year 2000 or later off-road compression-ignition
engines must be designed, built and equipped to meet the State’s stringent anti-smog standards. In all
states, 1998 and later non-road compression-ignition engines must be designed, built and equipped to meet
the United States EPA emissions standards. Yanmar warrants the emission control system on your engine
for the periods of time listed below provided there has been no abuse, neglect or improper maintenance of
your engine.
Your emission control system may include parts such as the fuel injection system and the air induction
system. Also included may be hoses, belts, connectors and other emission-related assemblies.
Where a warrantable condition exists, Yanmar will repair your non-road compression-ignition engine at no
charge to you including diagnosis, parts and labor.
Manufacturer’s Warranty Period:
The model year 1998 or later certified and labeled non-road compression-ignition engines are warranted for
the periods listed below. If any emission-related part on your engine is found to be defective during the
applicable warranty period, the part will be replaced by Yanmar.
Engine Type Warranty Period by Number of Years or Hours of Operation
Constant speed engines rated at or above
50 hp (37 kW)
Constant speed engines rated under 50 hp
SAE (37 kW) with rated speeds greater than
or equal to 3,000 rpm
Engines rated at or above 26 hp (19 kW) Warranty period is five (5) years or 3,000 hours of use, whichever occurs first. In
Engines rated under 26 hp (19 kW) Warranty period is two (2) years or 3,000 hours of use, whichever occurs first. In
Warranty period is five (5) years or 3,000 hours of use, whichever occurs first. In
the absence of a device to measure hours of use, the engine has a warranty
period of five (5) years.
Warranty period is two (2) years or 3,000 hours of use, whichever occurs first. In
the absence of a device to measure hours of use, the engine has a warranty
period of two (2) years.
the absence of a device to measure hours of use, the engine has a warranty
period of five (5) years.
the absence of a device to measure hours of use, the engine has a warranty
period of two (2) years.
TNE Service Manual
2-5
YANMAR WARRANTIES
Limited Emission Control System Warranty - USA Only - Continued
Warranty Coverage:
This warranty is transferable to each subsequent purchaser for the duration of the warranty period. Repair or
replacement of any warranted part will be performed at an authorized Yanmar dealer.
Warranted parts not scheduled for replacement as required maintenance in the Operation Manual shall be
warranted for the warranty period. Warranted parts scheduled for replacement as required maintenance in
the owner’s manual are warranted for the period of time prior to the first scheduled replacement. Any part
repaired or replaced under warranty shall be warranted for the remaining warranty period.
During the warranty period, Yanmar is liable for damages to other engine components caused by the failure
of any warranted part during the warranty period.
Any replacement part which is functionally identical to the original equipment part in all respects may be
used in the maintenance or repair of your engine, and shall not reduce Yanmar’s warranty obligations.
Add-on or modified parts that are not exempted may not be used. The use of any non-exempted add-on or
modified parts shall be grounds for disallowing a warranty.
Warranted Parts:
This warranty covers engine components that are a part of the emission control system of the engine as
delivered by Yanmar to the original retail purchaser. Such components may include the following:
• Fuel Injection System
• Cold Start Enrichment System
• Intake Manifold
• Turbocharger Systems
• Exhaust Manifold
• Positive Crankcase Ventilation System
• Hoses, belts, connectors and assemblies associated with emission control systems
Since emissions related parts may vary slightly between models, certain models may not contain all of these
parts and other models may contain the functional equivalents.
2-6 TNE Service Manual
Limited Emission Control System Warranty - USA Only - Continued
YANMAR WARRANTIES
Exclusions:
Failures other than those arising from defects in
material and / or workmanship are not covered by
this warranty. The warranty does not extend to the
following: malfunctions caused by abuse, misuse,
improper adjustment, modification, alteration,
tampering, disconnection, improper or inadequate
maintenance or use of non-recommended fuels
and lubricating oils; accident-caused damage, and
replacement of expendable items made in
connection with scheduled maintenance. Yanmar
disclaims any responsibility for incidental or
consequential damages such as loss of time,
inconvenience, loss of use of equipment / engine or
commercial loss.
Owner’s Warranty Responsibilities:
As the engine owner, you are responsible for
the performance of the required maintenance
listed in your owner’s manual. Yanmar
recommends that you retain all documentation,
including receipts, covering maintenance on your
non-road compression-ignition engine, but Yanmar
cannot deny warranty solely for the lack of receipts,
or for your failure to ensure the performance of all
scheduled maintenance.
Yanmar may deny your warranty coverage of your
non-road compression-ignition engine or a part has
failed due to abuse, neglect, improper maintenance
or unapproved modifications.
Your engine is designed to operate on diesel fuel
only. Use of any other fuel may result in your engine
no longer operating in compliance with applicable
emissions requirements.
You are responsible for initiating the warranty
process. You must present your engine to a Yanmar
dealer as soon as a problem exists. The warranty
repairs should be completed by the dealer as
expeditiously as possible. If you have any questions
regarding your warranty rights and responsibilities,
or would like information on the nearest Yanmar
dealer or authorized service center, you should
contact Yanmar America Corporation at
1-800-872-2867.
TNE Service Manual
2-7
YANMAR WARRANTIES
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2-8 TNE Service Manual
TNE Service Manual
Section 3
SAFETY
SAFETY STATEMENTS
Yanmar is concerned for your safety and your
machine’s condition. Safety statements are one of
the primary ways to call your attention to the
potential hazards associated with Yanmar TNE
engine operation. Follow the precautions listed
throughout the manual before operation, during
operation and during periodic maintenance
procedures for your safety, the safety of others and
to protect the performance of your engine. Keep the
labels from becoming dirty or torn and replace
them if they are lost or damaged. Also, if you need
to replace a part that has a label attached to it,
make sure you order the new part and label at the
same time.
This safety alert symbol appears with
most safety statements. It means
A
attention, become alert, your safety is
involved! Please read and abide by the
message that follows the safety alert
symbol.
A DANGER
Danger (the word “DANGER” is in white
letters with a red rectangle behind it) –
indicates an imminently hazardous
situation which, if not avoided, will
result in death or serious injury. Danger
is limited to the most extreme
situations.
0000001en
A WARNING
Warning (the word “WARNING” is in
black letters with an orange rectangle
behind it) – indicates a potentially
hazardous situation which, if not
avoided, could result in death or serious
injury.
0000001en
A CAUTION
Caution (the word “CAUTION” is in black
letters with a yellow rectangle behind it)
– indicates a potentially hazardous
situation which, if not avoided, may
result in minor or moderate injury.
0000001en
CAUTION
Caution without the safety alert symbol
indicates a potentially hazardous
situation that can cause damage to the
machine, personal property and / or the
environment or cause the machine to
operate improperly.
0000001en
TNE Service Manual
3-1
SAFETY
SAFETY PRECAUTIONS
Before You Operate
CAUTION
NEVER permit anyone to operate the
engine or driven machine without proper
training.
• Read and understand this Operation
Manual before you operate the
machine to ensure that you follow safe
operating practices and maintenance
procedures.
• Machine safety signs and labels are
additional reminders for safe operating
and maintenance techniques.
• See your authorized Yanmar industrial
engine dealer or distributor for
additional training.
0000002en
During Operation and Maintenance
A DANGER
SCALD HAZARD!
• NEVER remove the radiator cap if the
engine is hot. Steam and hot engine
coolant will spurt out and seriously
burn you. Allow the engine to cool
down before you attempt to remove
the radiator cap.
• Securely tighten the radiator cap after
you check the radiator. Steam can
spurt out during engine operation if
the cap is loose.
• ALWAYS check the level of engine
coolant by observing the reserve tank.
• Failure to comply will result in death or
serious injury.
0000002en
A DANGER
EXPLOSION HAZARD!
• Keep the area around the battery well
ventilated. While the engine is running
or the battery is charging, hydrogen
gas is produced which can be easily
ignited.
• Keep sparks, open flame and any other
form of ignition away.
• Failure to comply will result in death or
serious injury.
0000003en
3-2 TNE Service Manual
SAFETY
A DANGER
FIRE AND EXPLOSION HAZARD!
• Diesel fuel is extremely flammable and
explosive under certain conditions.
• When you remove any fuel system
component to perform maintenance
(such as changing the fuel filter) place
an approved container under the
opening to catch the fuel.
• NEVER use a shop rag to catch the
fuel. Vapors from the rag are extremely
flammable and explosive.
• Wipe up any spills immediately.
• Wear eye protection. The fuel system
is under pressure and fuel could spray
out when you remove any fuel system
component.
A DANGER
FIRE AND EXPLOSION HAZARD!
• Diesel fuel is extremely flammable and
explosive under certain conditions.
• NEVER remove the fuel cap with
engine running.
• Failure to comply will result in death or
serious injury.
0000011en
• Failure to comply will result in death or
serious injury.
0000009en
A DANGER
FIRE AND EXPLOSION HAZARD!
• Diesel fuel is extremely flammable and
explosive under certain conditions.
• NEVER use diesel fuel as a cleaning
agent.
• Failure to comply will result in death or
serious injury.
0000012en
TNE Service Manual
3-3
SAFETY
A DANGER
FIRE AND EXPLOSION HAZARD!
• Diesel fuel is extremely flammable and
explosive under certain conditions.
• 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
immediately. ALWAYS close the air
bleed port after you complete priming
the system.
• Wear eye protection. The fuel system
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
A DANGER
FIRE AND EXPLOSION HAZARD!
• Only use the key switch to start the
engine.
• NEVER jump start the engine. Sparks
caused by jumping the battery to the
starter terminals may cause a fire or
explosion.
• Failure to comply will result in death or
serious injury.
0000004en
0
A DANGER
FIRE AND EXPLOSION HAZARD!
• Diesel fuel is extremely flammable and
explosive under certain conditions.
• Only fill fuel tank with diesel fuel.
Filling fuel tank with gasoline may
result in a fire.
• NEVER refuel with engine running.
• Wipe up all spills immediately.
• Keep sparks, open flames or any other
form of ignition (match, cigarette,
static electric source) away when
fueling / refueling.
• NEVER overfill the fuel tank.
• Fill fuel tank and store fuel in a
well-ventilated area only.
• Failure to comply will result in death or
serious injury.
3-4 TNE Service Manual
0000005en
SAFETY
0
A DANGER
FIRE AND EXPLOSION HAZARD!
• Diesel fuel is extremely flammable and
explosive under certain conditions.
• Before you operate the engine, check
for fuel leaks. Replace rubberized fuel
hoses every two years or every 2000
hours of engine operation, whichever
comes first, even if the engine has
been out of service. Rubberized fuel
lines tend to dry out and become
brittle after two years or 2000 hours of
engine operation, whichever comes
first.
• Failure to comply will result in death or
serious injury.
0000015en
A DANGER
CRUSH HAZARD!
• When you need to transport an engine
for repair have a helper assist you
attach it to a hoist and load it on a
truck.
• NEVER stand under hoisted engine. If
the hoist mechanism fails, the engine
will fall on you, causing serious injury
or death.
• Failure to comply will result in death or
serious injury.
0000008en
A DANGER
EXPLOSION HAZARD!
• NEVER check the remaining battery
charge by shorting out the terminals.
This will result in a spark and may
cause an explosion or fire. Use a
hydrometer to check the remaining
battery charge.
• If the electrolyte is frozen, slowly warm
the battery before you recharge it.
• Failure to comply will result in death or
serious injury.
0000007en
TNE Service Manual
3-5
SAFETY
A WARNING
SEVER HAZARD!
• Keep hands and other body parts
away from moving / rotating parts
such as the cooling fan, flywheel or
PTO shaft.
• Wear tight fitting clothing and keep
your hair short or tie it back while the
engine is running.
• Remove all jewelry before you operate
or service the machine.
• NEVER start the engine in gear.
Sudden movement of the engine
and / or machine could cause death or
serious personal injury.
• NEVER operate the engine without the
guards in place.
• Before you start the engine make sure
that all bystanders are clear of the
area.
A WARNING
EXHAUST HAZARD!
• NEVER operate the engine in an
enclosed area such as a garage,
tunnel, underground room, manhole or
ship’s hold without proper ventilation.
• NEVER block windows, vents, or other
means of ventilation if the engine is
operating in an enclosed area. All
internal combustion engines create
carbon monoxide gas during
operation. Accumulation of this gas
within an enclosure could cause
illness or even death.
• Make sure that all connections are
tightened to specifications after repair
is made to the exhaust system.
• Failure to comply could result in death
or serious injury.
0000003en
• Keep children and pets away while the
engine is operating.
• 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
or serious injury.
0000002en
A WARNING
ALCOHOL AND DRUG HAZARD!
• 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
SAFETY
A WARNING
EXPOSURE HAZARD!
• Wear personal protective equipment
such as gloves, work shoes, eye and
hearing protection as required by the
task at hand.
• NEVER wear jewelry, unbuttoned
cuffs, ties or loose fitting clothing
when you are working near
moving / rotating parts such as the
cooling fan, flywheel or PTO shaft.
• ALWAYS tie long hair back when you
are working near moving / rotating
parts such as a cooling fan, flywheel,
or PTO shaft.
• NEVER operate the engine while
wearing a headset to listen to music or
radio because it will be difficult to hear
warning signals.
A WARNING
BURN HAZARD!
• Batteries contain sulfuric acid. NEVER
allow battery fluid to come in contact
with clothing, skin or eyes. Severe
burns could result. ALWAYS wear
safety goggles and protective clothing
when servicing the battery. If contact
with the skin and / or eyes should
occur, flush with a large amount of
water and obtain prompt medical
treatment.
• Failure to comply could result in death
or serious injury.
0000007en
A WARNING
• Failure to comply could result in death
or serious injury.
0000005en
HIGH PRESSURE HAZARD!
• Avoid skin contact with high pressure
diesel fuel spray caused by a fuel
system leak such as a broken fuel
injection line. High pressure fuel can
penetrate your skin and result in
serious injury. If you are exposed to
high pressure fuel spray obtain
prompt medical treatment.
• NEVER check for a fuel leak with your
hands. ALWAYS use a piece of wood
or cardboard. Have your authorized
Yanmar industrial engine dealer or
distributor repair the damage.
• Failure to comply could result in death
or serious injury.
0000008en
TNE Service Manual
3-7
SAFETY
A WARNING
SHOCK HAZARD!
• Turn off the battery switch (if
equipped) or disconnect the negative
battery cable before servicing the
electrical system.
• Check the electrical harnesses for
cracks, abrasions, and damaged or
corroded connectors. ALWAYS keep
the connectors and terminals clean.
• Failure to comply could result in death
or serious injury.
0000009en
A WARNING
A WARNING
BURN HAZARD!
• If you must drain the engine oil while it
is still hot, stay clear of the hot engine
oil to avoid being scalded. Make sure
you wear eye protection.
• Failure to comply could result in death
or serious injury.
0000011en
A WARNING
BURN HAZARD!
SEVER HAZARD!
• Stop the engine before you begin to
service it.
• NEVER leave the key in the key switch
when you are servicing the engine.
Someone may accidentally start the
engine and not realize you are
servicing it. This could result in a
serious injury.
• If you must service the engine while it
is operating, remove all jewelry, tie
back long hair, and keep your hands,
other body parts and clothing away
from moving / rotating parts.
• Failure to comply could result in death
or serious injury.
0000010en
• Wait until the engine cools before you
drain the engine coolant. Hot engine
coolant may splash and burn you.
• Failure to comply could result in death
or serious injury.
0000016en
3-8 TNE Service Manual
SAFETY
A WARNING
BURN HAZARD!
• Keep your hands, and other body
parts, away from hot engine surfaces
such as the muffler, exhaust pipe,
turbocharger (if equipped) and engine
block during operation and shortly
after you shut the engine down. These
surfaces are extremely hot while the
engine is operating and could
seriously burn you.
• Failure to comply could result in death
or serious injury.
0000015en
A CAUTION
A CAUTION
FLYING OBJECT HAZARD!
• ALWAYS wear eye protection when
servicing engine and when using
compressed air or high-pressure
water. Dust, flying debris, compressed
air, pressurized water or steam may
injure your eyes.
• Failure to comply may result in minor
or moderate injury.
0000003en
CAUTION
• Only use diesel fuels recommended by
Yanmar for the best engine
performance, to prevent engine
damage and to comply with EPA / ARB
warranty requirements.
COOLANT HAZARD!
• Wear eye protection and rubber gloves
when you handle Long Life or
Extended Life engine coolant. If
contact with the eyes or skin should
occur, wash immediately with clean
water.
• Failure to comply may result in minor
or moderate injury.
0000005en
• Only use clean diesel fuel.
• NEVER remove primary strainer from
the fuel tank filler port (if equipped). If
removed, dirt and debris could get into
the fuel system causing it to clog.
0000004en
CAUTION
NEVER attempt to adjust the low or high
idle speed limit screw. This may impair
the safety and performance of the
machine and shorten its life. If
adjustment is ever required, contact
your authorized Yanmar industrial
engine dealer or distributor.
0000045en
TNE Service Manual
3-9
SAFETY
CAUTION
If any problem is noted during the visual
check, the necessary corrective action
should be taken before you operate the
engine.
0000021en
CAUTION
NEVER hold the key in the START
position for longer than 15 seconds or
the starter motor will overheat.
0000007en
CAUTION
The illustrations and descriptions of
optional equipment in this manual, such
as the operator’s console, are for a
typical engine installation. Refer to the
documentation supplied by the optional
equipment manufacturer for specific
operation and maintenance instructions.
0000018en
CAUTION
Observe the following environmental
operating conditions to maintain engine
performance and avoid premature
engine wear:
• Avoid operating in extremely dusty
conditions.
• Avoid operating in the presence of
chemical gases or fumes.
• Avoid operating in a corrosive
atmosphere such as salt water spray.
• NEVER install the engine in a
floodplain unless proper precautions
are taken to avoid being subject to a
flood.
• NEVER expose the engine to the rain.
0000003enTNE
CAUTION
If any indicator illuminates during
engine operation stop the engine
immediately. Determine the cause and
repair the problem before you continue
to operate the engine.
0000029en
3-10 TNE Service Manual
SAFETY
CAUTION
Observe the following environmental
operating conditions to maintain engine
performance and avoid premature
engine wear:
• NEVER run the engine if the ambient
temperature is above +104°F (+40°C)
or below +5°F (-15°C).
◆ If the ambient temperature exceeds
+104°F (+40°C) the engine may
overheat and cause the engine oil to
break down.
◆ If the ambient temperature falls
below +5°F (-15°C) rubber
components such as gaskets and
seals will harden causing premature
engine wear and damage.
◆ Contact your authorized Yanmar
industrial engine dealer or
distributor if the engine will be
operated in either temperature
extreme.
• Contact your authorized Yanmar
industrial engine dealer or distributor
if you need to operate the engine at
high altitudes. At high altitudes the
engine will lose power, run rough, and
produce exhaust gases that exceed
the design specifications.
0000065enTNE
CAUTION
• Only use the engine oil specified.
Other engine oils may affect warranty
coverage, cause internal engine
components to seize, or shorten
engine life.
• Prevent dirt and debris from
contaminating engine oil. Carefully
clean the oil cap / dipstick and the
surrounding area before you remove
the cap.
• NEVER mix different types of engine
oil. This may adversely affect the
lubricating properties of the engine oil.
• NEVER overfill. Overfilling may result
in white exhaust smoke, engine
overspeed or internal damage.
0000005en
CAUTION
• Only use the engine coolant specified.
Other engine coolants may affect
warranty coverage, cause an internal
build up of rust and scale and / or
shorten engine life.
• Prevent dirt and debris from
contaminating engine coolant.
Carefully clean the radiator cap and
the surrounding area before you
remove the cap.
TNE Service Manual
• NEVER mix different types of engine
coolants. This may adversely affect the
properties of the engine coolant.
0000006en
CAUTION
• NEVER overfill the engine with engine
oil.
• ALWAYS keep the oil level between
upper and lower lines on the dipstick.
0000015en
3-11
SAFETY
CAUTION
For maximum engine life, Yanmar
recommends that when shutting the
engine down, you allow the engine to
idle, without load, for 5 minutes. This
will allow the engine components that
operate at high temperatures, such as
the turbocharger (if equipped) and
exhaust system, to cool slightly before
the engine itself is shut down.
0000008en
CAUTION
NEVER use an engine starting aid such
as ether. Engine damage will result.
0000009en
CAUTION
Make sure the engine is installed on a
level surface. If a continuously running
engine is installed at an angle greater
than 20° (in any direction) or if an engine
runs for short periods of time (less than
3 minutes) at an angle greater than 25°
in any direction, engine oil may enter the
combustion chamber causing exessive
engine speed and generate white
smoke. This may cause serious engine
damage.
0000010enTNE
CAUTION
New Engine Break In:
• On the initial engine start-up, allow the
engine to idle for approximately 15
minutes while you check for proper
engine oil pressure, diesel fuel leaks,
engine oil leaks, coolant leaks, and for
proper operation of the indicators
and / or gauges.
• During the first hour of operation, vary
the engine speed and load on the
engine. Short periods of maximum
engine speed and load are desirable.
Avoid prolonged operation at
minimum or maximum engine speeds
and loads for the next 4 to 5 hours.
• During the break-in period, carefully
observe the engine oil pressure and
engine temperature.
• During the break-in period, check the
engine oil and coolant levels
frequently.
0000011en
CAUTION
NEVER engage the starter motor while
the engine is running. This may damage
the starter motor pinion and / or ring
gear.
0000012en
3-12 TNE Service Manual
SAFETY
CAUTION
• NEVER attempt to modify the engine’s
design or safety features such as
defeating the engine speed limit
control or the fuel injection quantity
control.
• Failure to comply may impair the
engine’s safety and performance
characteristics and shorten the
engine’s life. Any alterations to this
engine may affect the warranty
coverage of your engine. See Yanmar
Limited Warranty on page 2-3.
0000044enTNESM
CAUTION
Be environmentally responsible. Follow
these procedures for hazardous waste
disposal. Failure to follow these
procedures may seriously harm the
environment.
• Follow the guidelines of the EPA or
other governmental agency for the
proper disposal of hazardous
materials such as engine oil, diesel
fuel and engine coolant. Consult the
local authorities or reclamation facility.
• NEVER dispose of hazardous
materials irresponsibly by dumping
them into a sewer, on the ground or
into ground water or waterways.
0000013en
CAUTION
Protect the air cleaner, turbocharger (if
equipped) and electric components
from damage when you use steam or
use high-pressure water to clean the
engine.
0000014en
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
CAUTION
NEVER attempt to adjust the low or high
idle speed limit screw. This may impair
the safety and performance of the
machine and shorten its life. If the idle
speed limit screws require adjustment,
see your authorized Yanmar industrial
engine dealer or distributor.
0000017en
CAUTION
The tightening torque in the Standard
Torque Chart (page 5-17) should be
applied only to the bolts with a “7” head.
(JIS strength classification: 7T)
• Apply 60% torque to
bolts that are not listed.
• Apply 80% torque when
tightened to aluminum alloy.
0000023enTNESM
TNE Service Manual
3-13
SAFETY
CAUTION
If any indicator fails to illuminate when
the key switch is in the ON position, see
your authorized Yanmar industrial
engine dealer or distributor for service
before operating the engine.
0000028en
CAUTION
Establish a periodic maintenance plan
according to the engine application and
make sure you perform the required
periodic maintenance at intervals
indicated. Failure to follow these
guidelines will impair the engine’s safety
and performance characteristics,
shorten the engine’s life and may affect
the warranty coverage on your engine.
See Yanmar Limited Warranty on
page 2-3.
Consult your authorized Yanmar
industrial engine dealer or distributor for
assistance when checking items marked
with a
z.
0000024enTNESM
CAUTION
It is important to perform daily checks
See Daily on page 5-19.
Periodic maintenance prevents
unexpected downtime, reduces the
number of accidents due to poor
machine performance and helps extend
the life of the engine.
0000060enTNESM
CAUTION
If the fuel filter / water separator is
positioned higher than the fuel level in
the fuel tank, water may not drip out
when the fuel filter / water separator
drain cock is opened. If this happens,
turn the air vent screw on the top of the
fuel filter / water separator 2-3 turns
counterclockwise.
Be sure to tighten the air vent screw
after the water has drained out.
0000025en
CAUTION
• When the engine is operated in dusty
conditions, clean the air cleaner
element more frequently.
• NEVER operate the engine with the air
cleaner or element(s) removed. This
may cause foreign material to enter the
engine and damage it.
0000026en
CAUTION
The maximum air intake restriction shall
be 0.90 psi (6.23 kPa; 635 mm Aq) or
less. Clean or replace the air cleaner
element if the air intake restriction
exceeds the above mentioned value.
0000046en
CAUTION
NEVER turn off the battery switch (if
equipped) or short the battery cables
during operation. Damage to the electric
system will result.
0000061en
3-14 TNE Service Manual
Section 4
GENERAL SERVICE
INFORMATION
TNE Service Manual
Table of Contents
Component Identification................................................................. 4-3
Location of Labels ........................................................................... 4-3
EPA / ARB Emission Control Regulations - USA Only.................... 4-4
Emission Control Labels.................................................................. 4-4
EPA / ARB Labels ..................................................................... 4-4
The 97/68/EC Directive Certified Engines....................................... 4-4
Engine Family.................................................................................. 4-5
Page
Function of Major Engine Components ........................................... 4-6
Function of Cooling System Components ....................................... 4-8
Diesel Fuel ...................................................................................... 4-9
Diesel Fuel Specifications ......................................................... 4-9
Filling The Fuel Tank............................................................... 4-10
Priming the Fuel System ......................................................... 4-12
Engine Oil...................................................................................... 4-14
Engine Oil Specifications......................................................... 4-14
Engine Oil Viscosity................................................................. 4-14
Checking Engine Oil................................................................ 4-15
Adding Engine Oil.................................................................... 4-15
Engine Oil Capacity (Typical) .................................................. 4-15
Engine Coolant.............................................................................. 4-16
Engine Coolant Specifications................................................. 4-16
Filling Radiator With Engine Coolant....................................... 4-17
Engine Coolant Capacity (Typical) .......................................... 4-18
Specifications ................................................................................ 4-19
Description of Model Number.................................................. 4-19
TNE Service Manual
4-1
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
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