Yanmar 4TNE94/98/106(T) Direct Ignition System Repair Service Manual

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This Workshop Service Repair manual PDF download for the 4TNE94/98/106(T) Direct Ignition System 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 Direct Ignition System 4TNE94/98/106(T)

Yanmar 4TNE94
Yanmar 4TNE98
Yanmar 4TNE106
Yanmar 4TNE106T


TABLE OF CONTENTS :

1.GENERAL
2.TROUBLESHOOTING
3.INSPECTION AND ADJUSTMENT
4.ENGINE BODY
5.LUBRICATION SYSTEM
6.COOLING SYSTEM
7.FUEL INJECTION SYSTEM / GOVERNOR
8.TURBOCHARGER (FOR 4TNE106T)
9.STARTING MOTOR
10.ALTERNATOR
11.SPECIAL SERVICE TOOLS
12.SERVICE STANDARDS


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Part Number : HINSHI-H8013-R1
Total Pages : 184


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 !!!!

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COVER
COVER
History of Correction
FOREWORD
0.1 FOREWORD
0.2 FOR SAFE SERVICING
0.3 PRECAUTIONS FOR SAFE SERVICING
(A) Service Shop(Place)
(B) Working Wear
(C) Tools to Be Used
(D) Use of Genuine Parts, Oil and Grease
(E) Bolt and Nut Tightening Torques
(F) Electrical Parts
(G) Waste Treatment
(H) Handling the Product
CONTENTS
1.GENERAL
1.1 ENGINE NOMENCLATURE
1.2 SPECIFICATIONS
1.3 FUEL OIL, LUBRICATING OIL AND COOLING WATER
1.4 ENGINE EXTERNAL VIEWS
1.5 STRUCTURAL DESCRIPTION
1.6 HOW TO READ THIS MANUAL
(1) Range of Operation Explanation
(2) How to Read The Explanations
(3) Definition of Terms
(4) Abbreviations
1.7 PRECAUTIONS FOR SERVICE WORK
1.8 TIGHTENING TORQUES FOR STANDARD BOLTS AND NUTS
2.TROUBLESHOOTING
2.1 QUICK REFERENCE TABLE FOR TROUBLESHOOTING
2.2 TROUBLESHOOTING BY MEASURING COMPRESSION PRESSURE
(1) Compression pressure measurement method
(2) Standard compression pressure
(3) Engine speed and compression pressure
(4) Measured value and troubleshooting
3.INSPECTION AND ADJUSTMENT
3.1 OIL INSPECTION
3.2 COOLING WATER INSPECTION
3.3 INSPECTING WATER LEAK FROM COOLING WATER SYSTEM AND RADIATOR
3.4 FAN BELT TENSION INSPECTION AND ADJUSTMENT
3.5 ADJUSTING THE VALVE CLEARANCE
3.6 INSPECTING THE FUEL INJECTION VALVE INJECTION PRESSURE AND SPRAY PATTERN
3.7 FUEL INJECTION TIMING INSPECTION AND ADJUSTMENT
3.8 ADJUSTING THE NO-LORD MAXIMUM (OR MINIMUM) REVOLUTIONS
3.9 SENSOR INSPECTION
3.10 BATTERY INSPECTION
3.11 ADJUSTING OPERATION
3.12 LONG STORAGE
3.13 PERIODIC MAINTENANCE SCHEDULE
4.ENGINE BODY
4.1 INTRODUCTION
4.2 CYLINDER HEAD
(1) Components
(2) Disassembly procedure
(3) Reassembly procedure
(4) Servicing points
(5) Parts inspection and measurement
(6) Valve seat correction
(7) Valve guide replacement
(8) Valve stem seal replacement
4.3 GEAR TRAIN AND CAMSHAFT
(1) Components
(2) Disassembly procedure
(3) Reassembly procedure
(4) Servicing points
(5) Parts inspection and measurement
(6) Oil seal replacement
(7) Camshaft bushing replacement
4.4 CYLINDER BLOCK
(1) Components
(2) Disassembly procedure
(3) Reassembly procedure
(4) Servicing points
(5) Parts inspection and measurement
(6) Cylinder bore correction
(7) Piston pin bushing replacement
(8) Oil seal replacement
5.LUBRICATION SYSTEM
5.1 LUBRICATION SYSTEM DIAGRAM
5.2 TROCHOID PUMP COMPONENTS
5.3 DISASSEMBLY
5.4 SERVICING POINTS
5.5 PARTS INSPECTION AND MEASUREMENT
6.COOLING SYSTEM
6.1 COOLING WATER SYSTEM
6.2 COOLING WATER PUMP COMPONENTS
6.3 DISASSEMBLY
6.4 SERVICING POINTS
7.FUEL INJECTION SYSTEM / GOVERNOR
7.1 INTRODUCTION
7.2 FUEL INJECTION PUMP
(1) Fuel system diagram
(2) Components
(3) Disassembly procedure
(4) Assembly procedure
(5) Servicing points
(6) Parts inspection and measurement
7.3 FUEL INJECTION VALVE
7.4 FUEL FEED PUMP
(1) Components
(2) Disassembly procedure
(3) Parts inspection and measurement
7.5 GOVERNOR
(1) Components
(2) Disassembly procedure
(3) Parts inspection and measurement
7.6 SPECIAL SERVICE TOOLS FOR DISASSEMBLY / ASSEMBLY
8.TURBOCHARGER (FOR 4TNE106T)
8.1 STRUCTURE AND FUNCTIONS
(1) Structural and functional outline
(2) Structure
(3) Components
8.2 SERVICE STANDARDS
(1) Service standards
(2) Tightening torque
8.3 PERIODIC INSPECTION PROCEDURE
(1) Periodic inspection intervals
(2) Inspection procedure
(3) Waste gate valve adjustment procedure
8.4 DISASSEMBLY PROCEDURE
(1) Preparation for disassembly
(2) Inspection before disasennbly
(3) Disassembly
8.5 WASHING AND INSPECTION PROCEDURE
(1) Washing
(2) Inspection procedure
8.6 REASSEMBLY PROCEDURE
(1) Preparation for reassembly
(2) Reassembly
8.7 HANDLING AFTER DISASSEMBLY AND REASSEMBLY
8.8 TROUBLESHOOTING
9.STARTING MOTOR
9.1 FOR 4TNE94/98
9.1.1 Specifications
9.1.2 Components
9.1.3 Troubleshooting
9.1.4 Names of Parts and Disassembly Procedure
9.1.5 Inspection and Maintenance
(1) Armature
(2) Field coil
(3) Blush
(4) Blush holder
(5) Magnetic switch
(6) Pinion clutch
9.1.6 Service Standards
9.1.7 Assembly
9.1.8 Characterstic Test
9.2 FOR 4TNE106(T)
9.2.1 Specifications
9.2.2 Configuration Drawing
9.2.3 Troubleshooting
9.2.4 Component Names and Disassembly Procedure
9.2.5 Disassembly Procedure
9.2.6 Inspection and Maintenance
(1) Armature
(2) Field coil
(3) Bursh
(4) Magnetic switch continuity test
(5) Pinion
(6) Ball bearing
9.2.7 Assembly
9.2.8 Adjustment
9.2.9 Service Standards
10.ALTERNATOR
10.1 FOR 4TNE94/98
10.1.1 Specifications
10.1.2 Sectional View
10.1.3 Troubleshooting
10.1.4 Parts names and Disassembly Procedure
10.1.5 Inspection and Overhaul
(1) Diode
(2) Rotor
(3) Stator
(4) Brush
(5) Check of IC regulator
10.1.6 Assembly
10.1.7 Service Standards
10.1.8 Performance Test
10.2 FOR 4TNE106(T)
10.2.1 Specifications
10.2.2 Exploded View
10.2.3 Troubleshooting
10.2.4 Disassembly Procedure
10.2.5 Inspection and Maintenance
10.2.6 Reassembly Procedure
10.2.7 Performance Test
11.SPECIAL SERVICE TOOLS
11.1 SPECIAL TOOLS
11.2 MEASURING INSTRUMENTS
12.SERVICE STANDARDS
12.1 ENGINE TUNING
12.2 ENGINE BODY
(1) Cylinder head
(2) Gear train and camshaft
(3) Cylinder block
12.3 LUBRICATING OIL SYSTEM (TROCHOID PUMP)
12.4 TIGHTENING TORQUES FOR MAIN BOLTS AND NUTS
COLOPHON
BACK COVER

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