Yanmar TNE Series Industrial Diesel Engine Repair Service Manual

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This Workshop Service Repair manual PDF download for the TNE Series Yanmar Industrial Diesel Engine has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.


APPLICABLE MODELS :

Yanmar 4TNE92 (EPA Tier2 & 3)
Yanmar 4TNE94L (EPA Tier2 Only)
Yanmar 4TNE98 (EPA Tier2 & 3)


TABLE OF CONTENTS :

Introduction
Yanmar Warranties
Safety
General Service Information
Periodic Maintenance
Engine
Fuel System
Cooling System
Lubrication System
Starter Motor
Alternator
Electric Wiring
Troubleshooting


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Part Number : OBTNE-G00200
Total Pages : 279


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.

This Service / Repair / Workshop Manual PDF Download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

Instant Download means there is NO shipping costs or waiting for a CD or paper manual to arrive in the mail!, You will receive this manual TODAY via Instant Download on completion of payment via our secure payment processor. We accept ALL major credit/debit cards/paypal.

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COVER
Introduction
Yanmar Warranties
Yanmar Limited Warranty
What is Covered by this Warranty?
How Long is the Warranty Period?
What the Engine Owner Must Do:
To Locate an Authorized Yanmar Industrial Engine
Dealer or Distributor:
What Yanmar Will Do:
What is Not Covered by this Warranty?
Warranty Limitations:
Warranty Modifications:
Questions:
Customer Registration
Yanmar Co., Ltd. Limited Emission Control
System Warranty - USA Only
Your Warranty Rights and Obligations:
California
All States
Manufacturer’s Warranty Period:
Warranty Coverage:
Warranted Systems / Parts Covered by this Warranty:
Exclusions:
Owner’s Warranty Responsibilities:
Safety
Safety Statements
Safety Precautions
Before You Operate
During Operation and Maintenance
General Service Information
Component Identification
Location of Labels
EPA / ARB Emission Control Regulations - USA Only
Emission Control Labels
EPA / ARB Labels
The 97/68/EC Directive Certified Engines
Engine Family
Function of Major Engine Components
Function of Cooling System Components
Diesel Fuel
Diesel Fuel Specifications
Additional Technical Fuel Requirements
Bio-Diesel Fuels
Filling The Fuel Tank
Priming the Fuel System
Engine Oil
Engine Oil Specifications
Service Categories
Definitions
Additional Technical Engine oil Requirements:
Engine Oil Viscosity
Checking Engine Oil
Adding Engine Oil
Engine Oil Capacity (Typical)
Engine Coolant
Engine Coolant Specifications
Alternative Engine Coolant
Additional Technical Coolant Specifications:
Filling Radiator With Engine Coolant
Engine Coolant Capacity (Typical)
Specifications
Description of Model Number
Engine Speed Specifications
Engine General Specifications
Principal Engine Specifications
4TNE92 EPA Tier2 & Tier3
4TNE94L EPA Tier2 Only
4TNE98 EPA Tier2
4TNE98 EPA Tier3
Engine Service Information
Engine Tuning
Tightening Torques for Standard Bolts and Nuts
Standard Torque Chart
Abbreviations and Symbols
Abbreviations
Symbols
Unit Conversions
Unit Prefixes
Prefix
Symbol
Power
Units of Length
Units of Volume
Units of Mass
Units of Force
Units of Torque
Units of Pressure
Units of Power
Units of Temperature
Periodic Maintenance
Precautions
The Importance of Periodic Maintenance
Performing Periodic Maintenance
Yanmar Replacement Parts
Required EPA / ARB Maintenance - USA Only
EPA / ARB Installation Requirements - USA Only
Tightening Fasteners
Standard Torque Chart
Periodic Maintenance Schedule
Periodic Maintenance Procedures
Daily
Drain Fuel Filter / Water Separator
Check Fuel Hoses and Engine Coolant Hoses
Every 250 Hours of Operation
Check and Clean Radiator Fins
Check and Adjust Cooling Fan V-belt
Check Battery
Clean Air Cleaner Element
Every 500 Hours of Operation
Replace Engine Oil and Engine Oil Filter
Check and Adjust the Governor Lever and Engine Speed Control
Every 1000 Hours of Operation
Adjust Intake / Exhaust Valve Clearance
Clean Fuel Filter / Water Separator
Replace Fuel Filter
Every 2000 Hours of Operation
Replace Air Cleaner Element
Inspect Clean and Test Fuel Injectors
Every 4000 Hours of Operation
Drain, Flush, and Re-fill the Coolant System with New Coolant
Replace Fuel Hoses and Engine Coolant Hoses
Engine
Engine Service Information
Engine Body
Cylinder Head
Intake / Exhaust Valve and Guide
Valve Spring
Rocker Arm and Shaft
Push Rod
Gear Train and Camshaft
Camshaft
Idler Gear Shaft and Bushing
Backlash of Each Gear
Cylinder Block
Crankshaft
Thrust Bearing
Piston
Piston Ring
Connecting Rod
Tappet
Engine Special Torque Chart
Special Service Tools
Measuring instruments
Before You Begin Servicing
Removal of Engine
Cylinder Head Components
Disassembly of Cylinder Head
Removal of Glow Plugs
Removal of Valve Cover
Removal of Rocker Arm Assembly
Disassembly of Rocker Arm Assembly
Removal of Cylinder Head
Removal of Intake / Exhaust Valves
Removal of Valve Guides
Cleaning of Cylinder Head Components
Inspection of Cylinder Head Components
Inspection of Push Rods
Inspection of Rocker Arm Assembly
Inspection of Valve Guides
Inspection of Cylinder Head
Inspection of Intake and Exhaust Valves
Inspection of Valve Springs
Assembly of Cylinder Head
Assembly of Valve Guides
Assembly of Intake and Exhaust Valves
Assembly of Cylinder Head
Assembly of Rocker Arm Assembly
Assembly of the Valve Cover
Assembly of Glow Plugs
Measuring and Adjusting Valve Clearance
Valve Clearance Measurement
Valve Clearance Adjustment
Drive Train and Camshaft Components
Disassembly of Drive Train and Camshaft Components
Removal of Oil Pan
Removal of Oil Sump Pump
Removal of Timing Gears
Removal of Pistons
Removal of Crankshaft
Removal of Camshaft
Removal of Gear Case
Inspection of Drive Train and Camshaft Components
Inspection of Cylinder Block
Inspection of Pistons
Inspection of Piston Pin
Inspection of Connecting Rod
Inspection of Tappets
Inspection of Crankshaft
Inspection of Camshaft
Inspection of Camshaft Bushings
Inspection of Idler Gear and Shaft
Honing and Boring
Assembly of Drive Train and Camshaft Components
Assembly of Pistons
Installation of Gear Case
Installation of Crankshaft
Installation of Pistons
Installation of Camshaft
Installation of Timing Gears
Installation of Gear Case Cover
Installation of Oil Sump Pump
Installation of Oil Pan
Fuel System
Fuel System Special Torque Chart
Measuring Instruments
Fuel System Components
Fuel System Diagram
Structure and Operation of Fuel Injection Pump
Overview
Pump
Governor
Timer
Feed Pump (Vane Type)
Regulating Valve
Plunger Operation
Process
Suction Process
Injection Process
End of Injection
Uniform Pressure Process
Reverse Rotation Prevention Mechanism
Fuel Injection Volume Adjustment Mechanism
Delivery Valve Assembly
Delivery Valve Holder with Damping Valve
All -Speed Governor
At Start of Engine
During Idling
At Full-Load Maximum Speed Control
At No-Load Maximum Speed Control
Full-Load Position Adjustment Mechanism
Structure and Operation of Timer
Standard Type Automatic Timer
Magnetic Valve (Stop Solenoid)
Before You Begin Servicing
Removal of Fuel Injection Pump
Installation of the Fuel Injection Pump
Checking / Adjustment of Fuel Injection Timing
Servicing the Fuel Injectors
Removal of the Fuel Injectors
Inspection and Testing of the Fuel Injectors
Test Procedure Using a Nozzle Tester
Judgement Criteria on Atomization Condition
Cleaning of Nozzle
Installation of Fuel Injectors
Cooling System
Measuring Instruments
Cooling System Diagram
Engine Coolant Pump Components
Before You Begin Servicing
Engine Coolant System Check
Disassembly of Engine Coolant Pump
Disassembly of the Coolant Pumps
Cleaning and Inspection
Thermostat
Radiator Cap
Assembly of Engine Coolant Pump
Assembly of All Coolant Pump Models
Lubrication System
Oil Pump Service Information
Engine Oil Pressure - All Models
Outer Rotor Outside Clearance - All Models
Outer Rotor Side Clearance - All Models
Outer Rotor to Inner Rotor Tip Clearance - All Models
Rotor Shaft Clearance - All Models
Lubrication System Diagram
Checking Engine Oil Pressure
Oil Pump Components
Before You Begin Servicing
Disassembly of Oil Pump
Cleaning and Inspection
Check Outer Rotor Outside Clearance
Outer Rotor to Inner Rotor Tip Clearance
Check Outer Rotor Side Clearance
Check Rotor Shaft Clearance
Assembly of Oil Pump
Starter Motor
Starter Motor Service Information
Starter Motor Troubleshooting
Starter Motor Precautions
Starter Motor Servicing
Starter Motor Components
Before You Begin
Starter Motor Removal
Starter Motor Disassembly
Inspection
Armature
Field Coil
Brush Holder
Magnetic Switch
Pinion Clutch Assembly
Starter Motor Assembly
Check Pinion Projection Length
No Load Test
Starter Motor Installation
Alternator
Alternator Service Information
Alternator Troubleshooting
Alternator Precautions
Alternator Components
Alternator Servicing
Before You Begin Servicing
Removal of Alternator
Disassembly of Alternator
Inspection
Stator Coil
Rotor
Rectifier
IC Regulator
Diode
Brush
Assembly of Brush Holder
Assembly of Alternator
Installation of Alternator
Bench Test
Test Wiring
Regulated Voltage Check
No Load Test
Output Test
Electric Wiring
Electric Wiring Precautions
Electrical Wire Resistance
Battery Cable Resistance
Electrical Wire Sizes - Voltage Drop
Conversion of AWG to European Standards
Electric Wiring Diagram (Reference)
Troubleshooting
Special Service Tools
Troubleshooting By Measuring Compression Pressure
Compression Pressure Measurement Method
Standard Compression Pressure
Engine Speed and Compression Pressure (Use for Reference)
Measured Value and Troubleshooting
Quick Reference Table For Troubleshooting
BACK COVER

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