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

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

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

{kgf/cm'} {125

-135}

Ignition order -

1-3-4-2

(No.1 cylinder

flywheel side)

Power take off -Flywheel

Direction

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,

2869

or A2

(cetane No. 45 min.)

Applicable lubricant -API grade class

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

700 (fan -flywheel)

Engine dimensions Overall width

508 (fuel filter -alternator)

Overall height

706 (oil pan -rocker cover upper surface)

Dry engine weight

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

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

90 90

70 70

60 60

8kW{45

4H~/2450rpm

50 50

'\.

30 30

---

l..---

----

\)~

.....-

--...

I \

20 20

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)

-"" z

600

500

400

300 0

I-

200

100

0 0

rfJ

0..

-""

:I:

" " "

'" '" '"

290

210 210

280

C/)

200 c

270 200 0

190

260

190

250

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

{18.2

kgfom}/1

,500

rpm

(Net)

178.

5Nm{18.

2kgf. m}/1500rpm \

Torque

0..

3::

:I:

-'"'

0..

100 100

90 90

70 70

44kW{59HP}/2450rpm

-.....

60 60

"""-!I..

::J

50 50

::J

30 30

20 20

10 10

0 0 0

/ V

\J~

V V

/'"

..-

l-/

Fuel

consumpt

'---..

-r

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

GENERAL

-'"' z

600

500

400

::J

300

I-

200

100

0..

-'"'

:I:

"'- "'- "'-

'" '" '"

290

210 210

280

::J

200 c

270 200 0

190

260

190

::J

250

180

HJZ06161

1-5

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

(f)

:I:

100 100

90 90

48.

9kW{65.

7H~/2400rpm

70 70

60 60

50 50

30 30

/ /

20 20

10 10

"""-

Fuel

consumpt

.......

-'"

600

500

400

300

1'\

200

100

0 0

(f)

-'"

:I:

"- "- "-

'" '" '"

/ \

290

210 210

280

200 200

270

190

260

190

250

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

GENERAL

1-4 Engine external views

4D92E194LE/98E

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

GENERAL

HJZ06164

12) Crankshaft pulley

4D92E,4D94LE,4D98E 1-9

1. GENERAL

1-5 Structural description

4D92E/94LE/98E

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

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

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