OPERATION MANUAL YANMAR YANMAR : ENGINE 4TNE9S4 -4TNESS 4TNE106 - 4TNE10GT Be sure to read this manual for safe and proper operation. Store this manual carefully after use.Thank you for purchasing a YANMAR Industrial Diesel Engine. [INTRODUCTION] @This Operation Manual covers the operation, maintenance, and precautions for the YANMAR Diesel Engine Series for industrial use : 4TNE94- 98+ 106-1067. The manual has been prepared with the actual user in mind and is organized around the following points. 1. For Your Safety : Warning symbols, safety seals, notices - contents and method. 2. Outline of Engine : Specifications and standard operation. 3. Preparation for Starting : Inspection & supply of fuel, lube oil, and cooling water before operation. 4. How to Operate : Starting, adjustment of operation speed, stopping, and storing for long Periods of time. 5. Maintenance & Inspection : Periodic inspection and maintenance (item, time, procedure). 6. Trouble and Troubleshooting : Simple problems and their countermeasures. @Read this Operation Manual carefully before using the engine to ensure correct operation and to maintain the engine in good working order. (@kcep this Operation Manual in a convenient place for easy access. @lf this Operation Manual is lost or damaged, order a new one from your dealer or distributor. @Make sure this manual is transferred to subsequent owners. This manual should be consid- ered a permanent part of the engine and remain with it. ©@Constant efforts are made to improve the quality and performance of Yanmar products, so some details included in this Operation Manual may differ slightly from your engine. If you have any questions about such differences please contact your Yanmar Dealer or Distributor. California California Proposition 65 Warning Proposition 65 Warning Battery posts, terminals, and related Diesel engine exhaust and some ofits Sees eee eee teat constitutions are known to the State of compounds, chemicals known to the culleatis ts Sass canes Wik ies State of California to cause cancer and reproductive harm. fie is Feoroaicas Netra Wash hand after handling ] Models YANMAR Diesel Engine | Industrial Series éTNE94~106T Code No. Operation Manual 49961-1013012. 3. 6. FOR YOUR SAFETY 1.1, Warming Symbols 1.2 Safety Precautions OUTLINE OF ENGINE - 2.1. Use & Driving System - 2.2 Engine Specifications 2.3. Names of Parts: 2.4. Major Servicing Parts 2.5 Control Equipment 2.5.1 Instruments and Alarm Devices 2.5.2 Operation Equipment ~~ PREPARATION FOR STARTING -- 3.1. Fuel Oil, Lube OIL and Cooling Water ~~ 3.2 Supplying with Fuel ~ 3.3 Supplying Engine Lube Oil 3.4 Supplying Cooling Water 3.5 Cranking ~~ 3.8 Checking and Resupplying Lube Oil and Cooling Water « HOW TO OPERATE 4.1 Inspection Before Starting 4.2 Checking the Alarm Devices 43 Starting 4.4 Adjusting the Engine Speed 4.5. Cautions During Operation 4.6 Stopping the Engine 4.7 Long Term Storage MAINTENANCE & INSPECTION --:- 5.1 General Inspection Rules 6.2 List of Periodic Inspections 5.3 Periodic Inspection Items 5.3.1 Inspection After Initial 50 Hrs. Operation 5.3.2 Inspection Every 50 Hours 5.3.3 Inspection Every 250 Hou 5.3.4 Inspection Every 500 Hrs. 5.3.5 Inspection Every 1000 Hrs. 5.3.6 Inspection Every 2000 Hrs. 5.4 Spare Parts . TROUBLE AND TROUBLESHOOTING -1. FOR YOUR SAFETY The precautions that need to be observed in order to operate your engine safely are noted throughout this manual. The symbols used and their meaning are explained below. 1.1. WARNING SYMBOLS oo Most operation, maintenance and inspection problems arise due to users failure to comply with the rules and precautions for safe operation described in this operation manual. Often, users do not understand or recognize the signs of approaching problems. Mishandling can ‘cause bums and other injuries and can result in death. Be sure you have read this operation manual carefully and understood it before operating the engine. Observe all of the instructions and precautions described. ‘The warning symbols used in this manual are explained below. DANGER- indicates an imminently hazardous A DANGER situation which, if not avoided, WILL result in death or serious injury. WARNING-indicates a potentially hazardous WN) situation which, if not avoided, COULD result in death or serious injury. CAUTION- indicates a potentially hazardous A CAUTION situation which, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practice. @ The descriptions captioned by [NOTICE] are particularly important cautions for handling. Ifyou ignore them, the performance of your machine may deteriorate leading to problems. In addition to this manual, there are safety seals on the operation side of the engine Be careful to follow any safety instructions on the seals and read carefully and follow any safety precautions noted in operation manuals for auxiliary machinery used.SAFETY PRECAUTIONS (Observe these instructions for your own safety.) Precautions for Operation &. Scalds Prevention @Never remove the radiator cap while the engine is still hot. Steam and hot water will spurt out and seriously burn you. Wait until the water temperature has dropped, then wrap a cloth around the cap and loosen it slowly. @Atter inspection, refasten the cap firmly. If the cap is not secure, steam or scald- ing water may be emitted during operation causing burns. Proper Ventilation of the Battery Area @Be sure the area around the battery is well-ventilated and there is nothing which could start a fire. During operation and charging, hydrogen gas is emitted from the battery and can be easily ignited. Fire Prevention @Be sure to use the correct type of fuel when refueling. Mistakenly filling with gasoline or the like will result in ignition. @Be sure to stop the engine before refueling, @ i you spill uel, wipe such spillage caretully. @Never place oils or other flammable material close to the engine as this could resultin ignition. Exhaust Gas @Be sure to establish good ventilation in the engine room with windows, vents, or ‘other ventilation equipment. Check again during operation to be sure that ventila- tion is good. Exhaust gas contains poisonous carbon monoxide and should not be inhaled. @Do not use the engine in rooms where the windows are closed, in tunnels, base- ments, manholes, ship holds, or other places where the exhaust gas cannot be prop-erly vented as this is dangerous. Moving Parts @Do not touch the moving parts of the engine (cooling fan, V-belt, pulley, etc.) during operation or let your clothing get caught in them as this can result in injury. @Never operate the engine without the covers on the moving parts. @Check before starting the engine to see that any tools or cloths used in mainte- nance have been removed from the area.Burns | @The whole engine is hot during operation and immediately after stopping. The tur- ms bocharger, exhaust manifold, exhaust pipe, intercooler and high pressure fuel —— pipe are very hot. Never touch these parts with your body or clothing, Alcohol @Never operate the engine while you are under the influence of alcohol or when you are ill or feel unwell as this results in accidents. Safety Precautions for Inspection Battery Fluid @Battery fluid is dilute sulfuric acid. It can blind you i it gets in your eyes, or burn your skin. Keep the fluid away from your body. Wash it off immediately with a large quantity of fresh water if you get any on you Fire by Electric Short-Circuits @Always turn off the battery switch or detach the earth cable (-) before inspecting the electrical system. Failure to do so could cause short-circuiting and fires. Stop Engine before Servicing, @Stop the engine before you service it. If you must inspect while the engine is oper-ating, never touch moving parts. Keep your body and clothing well clear of all moving parts as this could result in injury. Scalds @if removing oil from the engine while it is still hot, do not let the oil splash you. @Wait until the temperature has dropped before removing cooling water from the engine to avoid getting scalded. [NOTICE] Do not alter the diesel engine. Rebuilding the engine or altering parts to increase the speed or the amount of fuel discharged, etc. will make operation unsafe, and result in damage and shortening of engine life. -- [NOTICE] Disposal of waste materials @Put oil or liquids to be disposed in a container. Never dispose of waste oil or other fluids outside, in a sewer, river, or the sea. @Treat waste materials safely observing all regulations and laws. Ask a waster recovery company to collect and dispose of it,2. Outline of Engine 2.1 Use&Driving System This engine is a vertical water-cooled diese! engine used to power construction and building ‘equipment, agricultural equipment, generators, and other types of industrial use machinery. @High power, high performance @Economical: efficient use of fuel and lube oil @Compact, easy handling and maintenance @Quiet: litte vibration and noise We are confident that you will be well satisfied with these and other fine features. The 4TNE94~106T series of engines generate their power from the flywheel side of the engine. There are two types of power generation: direct and belt driven. For the direct type, the auxiliary machinery is connected at the flywheel housing or the back plate. For the belt driven type, the auxiliary machinary is connected to the V-belt pulley of the bearing on the flywheel side. When there is no V-belt pulley on the bearing and the machinery is connected directly, there are limita- tions on the power generation. Consult your YANMAR dealer. Attaching a heavy load can dam- age the crank shat, Power can also be generated from the opposite side of the flywheel, however, the position of the radiator and other parts must be altered. Consult your YANMAR dealer. The main parts have been standardized to allow you to use the engine for a large variety of aux- iliary machinary. Other parts (fuel tank, radiator, cooling fan, air cleaner, silencer, remote control equipment, instruments and alarm devices, sensors) have options to allow you to make the best possible selection for your individual use. Specialized knowledge and skills are required to equip and install these engines. Consult your YANMAR dealer or distributor. @ Consult your YANMAR dealer or distributor on selecting the best options for your pur pose and conditions. © tis important to select the best engine for the auxiliary machinery to be used in order to ensure optimum engine performance and to guard against damage and accidents. © In addition to correctly installing the engine, itis important to install safe cooling water and exhaust pipes and electric wiring, © Depending on the purpose for which the engine is used, an official inspection may be required by law. This manual explains the procedures for operating engines of standard specifications. Deviations from the standard are explained in sections with the following marks, Model Number : Information for this model engine only. Where no model number is specified, information is relevant for all models. Be careful to follow the instructions and precautions set down in this operation manual. Option : Information on equipment options. Be sure to read the operation manual from the manufacturer of the auxiliary machinary you plan (on using for information on how to select the proper options for your diesel engine. —4‘The model name for the 4TNE94~106T series of engines is explained below. 4 TNE 94 (T) -OO Model | | Lo Classification number | ——— Engine with turbocharger |______________________ inside cylinder (mm) ——ee es Engine series No. of cylinders (4) The 4TNE94~106T series is divided into 2 categories according to rom. Mark | Engine Speed (rpm) Auxiliary Machinery vM 2000 ~ 2500 | Tractor, Construction Equipment, Industrial-use machinery cL 1500 or 1800 4-polar dynamo, Water pump VM: Variable, Medium speed CL: Constant,Low sped 4TNE94~106T Series Engine Specifications Type Vertical water-cooled 4-cycle diesel engine ‘Swit pre-combustion ATNESA Combustion system |-—— Direct injection ATNE94, 4TNE98, 4TNE106, 4TNETO6T Starter system | Electric starting Cooling system Radiator | Lubrication system Forced lubrication with Trochid pump Power output position Flywheel side Direction of rotation | __Counterclockwise when viewed from flywheel side2.2.1 4TNE94 (Direct injection) Engine Specifications Engine model “NESE Combustion system 8 Direct injection, No turbocharger No. of cyinders-BoreXStroke mm = 4-94 100° Displacement @ — 2.775 Engine specifications : VM cL Revolution rpm] 2000 2200 2400 2500 3500 1800 ‘Cont. rating output KWiho} = —— [2 (5.01 | 31.9 142.0) ‘Max. rating output kWihp}| 35.3 147.3] | 36.2 [51.2! | 41.6 (55.7) | 43.0 157.6! | 29.1 (39.0) | 34.6 (46.4) NoloadMaxirumspeeé cpm | 21g0%25 | 2ao025 | 250025 | 2700t25 | 167525 | 187006 tube oi [Ful _ |. capacity [eteave 4a Cooling water capacity @ 4.2 (Engine only) Starting output oo ~ 12v-2.3KW ‘Aternatorcapacy 12v-40A Dimensions UXWXH mm 720x808xe60 Dry weight ry 223 Recommended bate capacty | ___12¥-66 or greater (5 hs rate) [Note] Engine dimensions and weight: With radiator cooling (an. (Radiator, exhaust silencer, and air cleaner ar not included) 2.2.2 4TNE94 (Swirl pre-combustion) Engine Specifications Engine model | aTNEDS Combustion system | ‘Swit pre-combustion No turbocharger No. ovine BoreXStoKe mn | 494X100 Displaceme 2) 2775 : Engine specications | vm Ca Revolution ‘pm L— 2480 = — : ‘Cont. rating output KWihp | = — = Max rating output KWIhp} | — 441 (saa) | — 7 Nelosd Maximum speed rpm | — — | arses = cn ee 75 : capacity [etecive 2 20 Cooling water capacity 2 | - 42 (Engine only) ‘Starting output 12V-2.5KW ‘Alternator capacity 12V-408, Dimensions LXWXH mm 700508706 Dry weight kg 225 = Recommended bay capacty 12V-64An or greater (5 hrs rate) [Note] Engine dimensions and weight: With radiator cooling fan. (Radlator, exhaust silencer, and ai leaner are not included)2.2.3 4TNE98_ Engine Specifications Engine model “aTNESB | Combustion system Direct injection, No turbocharger No fender Boe XSroke mn | 498X110 Displacement 2 7 318 Engine specications vM cu Revolution rem] 2000 | 2200 | 2400 2500 1500 1800 Cont. rating output KWinp} | — = = 309 41.4) | 96.8 (4031 Max. rating output KAhp!| 41.9 (58.1) | 45.6 (61.11 | 49.3 (66.1) | 51.1 (68s! | 946 [46.41 | 412 (55.2 Totatmanmeped om | 7025 | zwoszs | asozzs | avoozes | vereues | so7o3es Lubeot [Ful] oa capaciy | etectve _# 44 Cooling water capacity 42 (Engine only) Staring output 12V.2.3kW Alternator capacity - 12V-40A Dimensions LXWXH = mm} 7 7 ~ 720X508 689 Dry weight "9 223 Recommended bat caacty 12V-64Ah or greater (5 hrs rate) | [Note] Engine dimensions and 2.2.4 4TNE106 Engine Specifications weight: With radiator cooling fn, (Radiator, exhaust silencer, and air cleaner are not included) Engine model “ATNE1O6 Combustion system No.of ender BoreSTART-+ON @Put the key in the starter switch. r @Turn the key from the OFF position to ON, _ Before Stating | Att Stating and check to see that the charge lamp Charge Lamp Gael on and lube oil pressure lamp come on as ee shown in the diagram to the right Lube Oil Pressure Lamp | On off [Before Starting]. The cooling water 7 Cooling Water | temperature lamp will not come on. Temperature Lamp a ou Itis important to check the alarm lamps again after the engine is started. All of the alarm lamps should be extinguished as shown in the diagram to the right [After Starting). By Sf Cening Water performing these procedures, it can be deter- Lube Oi Pressure AlamLanp | arm tarp mined whether or not the alarm devices are Heater Lamp in good working order. if the alarm devices are not working properly, consult your YAN- Starter Switch’ MAR dealer. 7 4.2.2 Checking Alarm Meters Before starting, the needle on the meter should be in a fixed position on the left side. The needles on the various meters will begin moving once the engine is started. Check the posi- tion of the needles to make sure there are no problems. @Tachometer Meter needle moves to indicate revolution speed. ®Cooling Water Temperature Meter Meter needle moves to indicate a rise in the water temperature. ©Lube Oil Pressure Meter Meter needle moves to indicate revolution speed The rated revolution speed is approximate- ly 4kgicm:4.3.1 Normal Starting Follow the following procedures for starting under normal conditions. @Cut off all clutches and main switches for all auxiliary machinery so there is no load. @Open the cocks for the oil/water sepa- rator and the fuel oil filter @Turn on the battery switch. @Put the key in the starter switch, Turn the key from the OFF position to ON checking to be sure that the alarm lamps are working properly. -See4.2.1 @Put the governor lever (accelerator mechanism) in the middle speed posi- tion. @Turn the key to START to start the engine. When the engine has started, remove your hand from the key. The key will automatically return to the ON position. Check to see that all alarm lamps have gone off. 4.3.2. Starting Under Low Temperature Conditions When starting the engine under difficult low temperature conditions (approximately 0’C or lower), use the air heater or glow plug| to enable easier starting Follow steps@)~® of the above procedure, and then follow the steps below. {NOTICE} Do not hold the starter switch on for longer than 15 secs. at a time, as this may result in overheating and dam- age. Remove hand after ‘engine star's, S—staRt le | Sarerowich——+ (NOTICE) Do not leave the heater or glow plug on for longer than 20 seconds at a time. Leaving the heater or glow plug on for longer periods of time will result in damage. @Turn the key from the OFF position to HEAT. The blue heater lamp will come on. Continue to hold the key in the HEAT position to allow the heater (glow plug) to warm up the engine. @When the heater lamp goes off after approximately 15 seconds, turn the key to START and start the engine. After the engine starts, remove your hand from the key. r Continue to hold the key in HEAT while the heater lamp is on 26 -4.3.3. Restarting After An Initial Failure When attempting to start the engine after an initial attempt to do so has failed, be sure that the engine is at a complete stop before turn- ing the starter switch key. When the engine will not start after several attempts, refer to [6. Trouble and Trouble- shooting] 4.3.4 Checking and Operating After Starting After the engine has started, run it at low speed and check the following. @Check the alarm lamps and devices to make sure they are working properly. See 4.2 @Check for water or oil leakage from the engine. @Check the color of the exhaust gas. @Check for abnormal sounds or vibra- tions. If there are no problems, run the engine at no-load for approximately 5 minutes. (This is called warming up and is per- formed to distribute oil to all the parts of the engine.) a {NOTICE} Turning the key to the START position when the engine is not fully stopped will damage the teeth of the starting gear. When restarting the engine, allow a peri- od of 30 seconds between attempts to allow the battery voltage to be restored. (NOTICE) If the engine is run at high speed or imme- diately hooked up to a load without the warming-up period, you run the risk of engine seizure.Adjust the speed of the engine with the gov- ermor lever (accelerator device). Move the lever slowly. [NOTICE] For a new engine be especially careful not to change speeds abruptly or attach a heavy load for the first 50 hours of opera tion. 28 {(4TNE94 Swiral pre-combustion)Always be on the lookout for problems during engine operation. Pay particular attention to the following. (1) Is the exhaust color normal? ‘The engine should never be operated when there is a continuous emission of black exhaust. The black color indicates engine overload which will shorten the life of the engine. (2) Are there abnormal vibrations or noise? Do not operate at speeds which produce violent vibrations. Depending on the structure of the auxiliary machinery, operation at certain speeds may result in resonance and heavy vibrations. Avoid operation in this speed range. If you hear any abnormal sounds, stop the engine and inspect. (3) Are any of the alarm lamps on? If an alarm lamp comes on during operation, do not panic. Reduce the engine speed to the low speed position, cut off the load from auxiliary machinery. After doing this, stop the engine and inspect. (4) Is there water, oil, or gas leakage, or are there any loose bolts? Check the engine room periodically for any problems. (6) Is there sufficient oil in the fuel tank? Replenish fuel oil in advance to avoid running out of fuel during operation. [NOTICE} Never turn off the battery switch or spark the battery cable during operation. Damage to parts in the electric system will result. Battery Switch al Stop the engine in accordance with the fol- lowing procedures. ‘Stopping the engine suddenly while oper- ating at high speed will make the engine temperature rise quickly causing deterio- ration of the oil and sticking of parts. Cut off the load from auxiliary machinery (clutch, main switch, etc). @Move the governor lever (accelerator device) to the low speed position, and cool down the engine for about 5 min- utes. In the rare instance where the engine does not stop when the starter switch key is turned to OFF, close the fuel filter fuel cock. The @Atter the engine has stopped, turn the starter switch to OFF, remove the key and place it in a safe place. engine will not stop immediately, but will stop @Cut off the battery switch. when the fuel runs out. Close the fuel tank cock. 294.7 Long Term Storage 7 When storing the engine for long periods of time, follow the procedure below. 4.7.1 Inspection and Maintenance for Long Storage Periods (1) Periodic Inspection It the time for a periodic inspection is close, perform it before storing the engine for a long peri- od of time. (2) Draining the Cooling Water When not using antifreeze, be sure to drain the water from the inside of the engine. / Wait until the temperature has dropped before removing cooling water %éx%. | trom the engine to avoid getting scalded. [NOTICE] If the water is not drained, it may freeze and damage parts of the cooling water system (radiator, cylinder block, cylinder head, etc.) ® rasan @Remove the radiator cap. @Loosen the drain plug at bottom of the radiator and drain off the cooling water. @aAfter draining the water, replace the radiator cap and tighten the drain plug. for the various engines. ei ‘The location of the drain plug differs. (8) Cleaning the Exterior, Draining the Fuel Oil, and Greasing @Ciean the outside of the engine wiping off any dust or oil. @To prevent condensation inside the fuel tank, either drain off the fuel or fil the tank, @Grease the joints and bearings of the accelerator cable. (4) Protecting the Engine From Moisture and Dust @Cover the air cleaner, silencer, electrical parts (alternator starter,switches) with vinyl sheets and seal them to prevent moisture and dust from entering, @Store the engine in a place which is dry and dust-tree and is well-ventilated. (6) Maintaining the Battery Charge @Cut off the battery switch or disconnect the earth cable (-). @Charge the battery once a month to compensate for the battery's self-discharge. 4.7.2 Checking the Engine for Reuse After a Long Storage Period ‘When using the engine after a long period of storage, prepare for operation in the same manner as for a new engine. +See [8. Preparation for Starting] 30Maintenance & Inspection Be Sure to Conduct Periodic Inspections. The functions of engine components will degenerate and engine performance will fall according to the age and use of the engine. If countermeasures are not taken, you may encounter unex- pected troubles during operation. Consumption of fuel or lube oil may become excessive and exhaust gas and engine noise may increase. These all shorten the life of the engine. Daily and periodic inspection and servicing will guard against accidents during operation. Inspect Before Starting. Make it a daily rule to inspect before starting. --See [4.1 Inspection Before Starting] Monitor the hour meter and conduct periodic inspections. Keep a daily record of operation and maintenance. When the time for an inspection approaches, study the relevant pages in the Operation Manual. Inspections should be made after 50,250,500, 1000, and 2000 hours of use. Use Genuine YANMAR Parts. Be sure to use genuine YANMAR parts for consumable and replacement parts. Use of other parts will reduce engine performance and shorten the life of the engine. Always Have Servicing Tools On Hand. Keep servicing tools close to the machinery and ready for use in inspections. Tightening Torque of Bolts & Nuts Itis important to tighten bolts and nuts properly to the correct tightening torque. Over-tightening damages the threads of the bolts and nuts and ruins them. Insufficient tightening causes oil leak- age from the installation face or damage to parts. Important parts must be tightened with a torque wrench to the correct tightening torque and in the right order. Consult with your dealer or distributor if servicing requires the removal of parts. The standard tightening torque for standard bolts & nuts is listed below. ¢ {NOTICE} AAA AAA A AaAA@______€_H—_________ © Apply the following tightening torque to bolts having "7" on the head. (ulS strength classification: 77) @ Tighten bolts with no. "7" mark to 60% tightening torque. @ Ifthe parts to be tightened are made from light alloy aluminum, tighten the @ bolts to 80% tightening torque. Mi0x15 5.0405 Bolt dia.Xpitch mm | _Mex1.0 | Maxt.25 wiax1.7s | maxis | Mrexts goto | 140410 | 23010 Tightening torque Kym | 11401 | 26403 3Daily and periodic inspection are important to keep the engine in its best condition. The following is a summary of inspection and servicing items by inspection interval. Periodic inspection vals vary depending on the uses, loads, fuels and lube oils used and handling conditions, and are hard to establish definitively. The following should be treated only as a general standard. [Section 5.3 Periodic Inspection Items] gives a detailed explanation of which parts must be inspected and the procedure for doing so for each interval. r—INOTICE} ‘Schedule your own periodic inspection plan according to the operational conditions of your engine and inspect every item. Neglecting periodic inspection leads to engine trou- bles and shortens the life of the engine. This mark @ indicates that inspection and servicing requires special knowledge and techniques. Consult your YANMAR dealer or distributor. O: Check ©: Replace @: Consult local dealer Interval oy term | Every | Every | Every | Every | Every 50h | 250hvs | soon {1,000hrs |2,000hrs Item Content Check & supply of oil to the tank ° Drain the fuel tank ic Drain the ue iter ($TNES4S wi pre-combustion) o Fuel oil Drain the ol/ water separator (Option) (© (Every 100n15) Clean the oilwater separator (Option) Replace the fuel filter element ° Check the quantity of lube oil ° Lube oil —_| Replace the lube oil {sire natin ater | Replace the lube oil filer element ‘ene0 atin ater | Check & supply of cooling water ° Clean radiator fins, ICooting 1eck the i ° eae | Check the V-bett tension ° Replace the cooling water ° Clean & check the cooling water passage e [Check the leak out of Fuel ol, Lube oll, Cooling water | Rubber hose | Check replace el pipe, cooling mater pipe e Clean air cleaner & replace element ° ° Intake system ~ Clean the Turbocharger blower e Electrical | Check the alarm lamps & devices oO Jequiement | Check & supply electrolyte in battery | O | [Cylinder head | Adjust the intake and exhaust va clearance | e ‘Check of fuel injection pressure & | y : Fuelpump & | atomizing condition “_ e injection valve | Check of fuel injection timing [ e —32—5.3.1. Inspection After Initial 50Hrs. Operation | {1) Replacing the Engine Lube Oil and Lube Oil Filters (1st time) During initial operation of the engine, the oil is quickly contaminated due to the initial wear of internal parts. The lube oil must therefore be replaced early. Replace the lube oil filter at the same time. Drain off the lube cil. 1) Put a container under the drain plug to catch the old oil 2) Remove the oil plug at the bottom of the oil pan to drain off the oil It is easier and more effective to drain the engine lube oil while the engine is still warm after operation. Be careful not to let hot oil splash on you and cause bums. af @Replace the lube oil filter. 1) Turn the lube oil filter to the left with the filter wrench and remove 2) Clean the filter installation face. 3) Put the new filter on the installation face, turn to the right by hand. Next, tighten an addition 3/4 of a turn with the filter wrench. (Tightening torque: 2.0 ~ 2.4kgf-m) Part Numbers: ~-See [5.4 Spare Parts] Fill with new lube oil. 1) Fill with the specified amount of oil. +See [2.2 Engine Items} 2)Run the engine for approximately 5 minutes and check to see if there is any oil leakage. 3) Approximately 10 minutes after stop- ping, check the oil level again with the oil dipstick and add more oil if necessary, From the 2nd time on, replace the oil every 250 hours. 33 —(2) Checking the Tension of the V-Belt of the Cooling Fan (Interval term) When the tension of the V-belt is weak, the cooling fan and the cooling pump will not work to cool the engine. This will cause the engine to overheat. Additionally, the alternator will not be charged. Check the tension of the V-belt in accordance with the following procedure. @Check the tension of the V-belt by pressing down with the index finger at the middle of the belt (point shown by finger). The give in the V-belt should measure about 10~15 at the depres- sion @To adjust the V-belt tension, loosen the set bolt and move the alternator. @Replace the belt if it is damaged. (NOTICE). If the V-belt tension is too tight, the belt will be damaged, and the bearings of the alternator and the cooling water pump will be damaged as well. Be careful not to spill any oil on the V-belt as this will lead to stretching and slip- page. (3) Inspection of Battery (Interval term) FON get any on you. z Ny @Aiways tum off the battery switch or detach the earth cable (—) before inspecting the electrical system. Failure to do so could @ cause short-circuiting and fires. @Be sure the area around the battery is well-ventilated and there is nothing which could start a fire. During operation and charging, hydrogen gas is emitted from the battery and can be easily ignited. @Battory fluid is dilute sulfuric acid. It can blind you if it gets in | == your eyes, or bum your skin. Keep the fluid away from your body. IGge= | Wash it off imme-ciately with a large quantity of fresh water if youCheck the level of fluid in the battery. When the amount of fluid nears the lower limit, fil with battery fluid (available in the market) to the upper limit. The battery ile is shortened if operation continues with insufficient battery | fluid. Battery fluid tends to evaporate more quickly in the summer, and the fluid level should be checked earlier than the specified times. Lower’ If the engine turns over at a slower than usual rate and refuses to start, recharge the bat- tery. If the engine still will not start after Follow the instructions and precautions in the Gianatepace ine satan manual from the battery maker. UPPE! 5.3.2_ Inspection Every 50 Hours (1) Draining the Fuel Tank Put a pan under the drain to catch the fuel @Loosen the drain plug at the bottom of the fuel tank, and drain off any water Drain Plug and dirt collected inside. @Once the water and dirt have been drained off and the fuel coming out is clear, close the drain plug Fuel Tank (2) Draining the Fuel Filter When dirt and water become mixed into the fuel, the fuel injection pump and valve will not function well. Drain off any deposits regularly. When the fuel filter is clogged, the fuel filter alarm lamp will come on. (Close the fuel cock. @Loosen the drain plug at the bottom of the fuel tank, and drain off any water and dirt collected inside. @Once the water and dirt have been drained off, close the drain plug. @Bleed the fuel system after reassem bling. —355.3.3 Inspection Every 250 Hours (1) Replacing the Engine Oil and Lube Oil Filter (2nd time & after) After the second oil change, the engine oil should be replaced after every 250 hours. Replace the lube oil filter at the same time. See 5.3.1(1). (2) Checking and Maintaining the Radiator Fins, When the radiator become dirty, the cool- ing capacity is reduced and causes the engine to overheat. Check the fins daily and clean whenever dirty. {NOTICE] Do not hold the pressurized air or water too close to the radiator or use a brush for cleaning, as this will damage the @Clean the around the fins with pressur- ized air (2kgt/em*). QWash the fins with neutral detergent and then rinse off by spraying with water. (3) Adjusting the Governor Lever & Accelerator Device The governor lever and the accelerator devices (accelerator lever, petal, etc.) of the auxiliary machinery are connected by an accelerator wire. If the wire becomes stretched or the connections loose deviation in the position may result ‘and make operation unsafe. Inspect the wire periodically and adjust if necessary. {NOTICE} Never remove the restraint bolt for the fuel injection pump or the restraint bolt on the amount of fuel injected. Doing so will impair safe operation and lower the effi- ciency of the engine and shorten its life. @Check to see that the governor lever on the engine side is touching the restraint bolt of the high speed side when the accelerator device is in the high speed position. @Check to see that the governor lever is touching the restraint bolt of the low speed side when the accelerator device is in the low speed position. Qf the governor lever does not touch the restraint bolt for either the high or low speed side when you check them, Jciysting Bot ~ loosen the setting screws on the fittings nn for the accelerator wire and adjust the & position of the wire. —36(4) Cleaning the Air Cleaner and Replacing the Element The efficiency of the engine is lowered when dirt and dust sucked in clogs the element. Clean the air cleaner periodically. Remove the clamp and take out the dust pan. @Pemove the butterfly bolt and take out the element. @Remove dirt on the outer surface of the element with pressurized air (2kgf/cm*) directed at the inner surface. @Replace the element if it is excessively dirty or damaged, @®Remove the inner lid to the dust pan and clean out the inside. @Reassemble the element. Put the inner lid of the dust pan back on with the top mark ( 1 TOP) pointing up. 5.3.4 Inspection Every 500 Hrs. Replacing the Fuel Filter Replace the element periodically. (1) Direct injection = [NOTICE] When using the engine in very dusty places, check the blower sooner than the prescribed times. SAC. (4TNE94 Swiral pre-combustion) {__ Ae Cieaner Filtering Element Disassemble and wash the inside before clogging reduces the flow of fuel. ‘@Close the fuel cock @By using the filter wrench, remove the fuel fiter. (Turn it counterclockwise) @Clean the filter mounting surface. @Set a new fuel filter and fully tighten ‘onto the mounting surface manually. ‘Then, tighten by about 1/2 turn by using the filter wrench.(Clockwise, tightening torque:1.2 to 1.6 kgf-m) Part code No. 119000-55600 @Open the fuel tank cock. @Since the fuel system contains air as a result of fuel filter replacement, bleed ir. (See 3.2.2) oS ae(2) Swirl pre-combustion (4TNE94) @Close the fuel cock. @Remove the drain plug at the bottom of the fuel fter and drain off the fuel inside. @By using the filter wrench, remove the fuel oil @Attach the drain plug at the bottom of the new fuel filter. Fuel Filter Part Code No.: 129901-55850 @Clean the fitter mounting surface. Fill the filter with fuel before attaching, Set a new fuel filter and fully tighten onto the mounting surface manually. Then, tighten by about 3/4 turn by using the filter wrench. (Clockwise, tightening torque: 1.4 kgf-m) Fuel filter Part code No. 129901-55850 @Since the fuel system contains air as a result of fuel filter replacement, bleed air. (See 3.2.2) lot of water has accumulated, disassemble (3) Washing the oil/water separator The cup under the oil/water separator is semi-transparent allowing you to see the contents of the cup. When water collects at the bottom of the cup, the red floating ring will rise. When a Fuel Fiter Tighten Close the fuel cock. @Loosen the retainer ring and remove the cup. Throw out the collected water and dit @Remove the element from the case and wash with clean fuel. If the mesh of the element is damaged, replace the ele- ment. Part Number ~* 171081-55910 @Return the element to the case. Put the floating ring and the coil spring into the cup and tighten the retainer ring @®Bleed the fuel system after reassem- and wash. Elemont Floating Ring Coll Spring Oxing- oinwater Retainer Ring Separator Drain the fuel tank whenever the oil/water separator is washed. bling. — See 3.2.2. 5.3.5 Inspection Every 1000 Hrs. (1) Replacing Cooling Water ~ See 5.3.2(1) Cooling performance drops when the cooling water is contaminated with rust and scale. Even if antifreeze or antirust is added, the cooling water must be periodically replaced because the properties of the agent will degenerate. Replace the cooling water once a year.@Draining the Cooling Water Wait ur —+See 4.7.1(2). he temperature has dropped before removing @Supplying Cooling Water cooling water from the engine See 3.4. to avoid getting scalded. (2) Inspecting and Adjusting of Intake/Exhaust Valve Clearance ‘Adjustment requires specialized knowledge and techniques. Consult your Yanmar dealer or distributor. Adjustment is necessary to correct any discrepancies in the timing of the opening and closing of the intake and exhaust valves. If adjustments are not made, the engine will ‘emit abnormal noises, and engine efficiency fall and damage will occur. (8) Inspecting and Adjusting the Fuel Injection Valve This inspection requires specialized knowledge and techniques. Consult your Yanmar dealer or distributor. Adjustment is necessary to obtain the optimal fuel injection to ensure the best possible engine performance. 5.3.6 Inspection Every 2000 Hrs. (1) Cleaning the Cooling Water System and Inspecting & Adjusting Parts This maintenance requires specialized knowledge and techniques. Consult your YANMAR dealer or distributor. Rust and scale are deposited inside the water cooling system during long periods of use and lower the cooling performance. In addition, when the oil cooler is dirty, the cooling efficiency of the engine oil is lowered and the oil quality deteriorates more quickly. Cleaning and maintenance of the parts shown below is necessary at the times when the cool- ing water is replaced. Relevant Cooling Water System Parts: Radiator, cooling water pump, thermostat, cylinder block, cylinder head, oil cooler, etc. (2) Inspecting and Replacing Fuel Oil Pipe and Cooling Water Pipe This maintenance requires specialized knowledge and techniques. Consult your YANMAR, dealer or distributor. Check the hoses used for the fuel oil and cooling water pipes and replace if damaged. @) Inspecting Fuel injection Timing This maintenance requires specialized knowledge. Consult your Yanmar dealer or distributor. Fuel injection timing must be adjusted to ensure optimal engine performance. —39—The table below shows the spare parts that should be replaced at the time of periodic inspec- Make the necessary preparations before the inspection time. Be sure to use genuine tions. YANMAR parts. Using other types of parts will lower engine efficiency and shorten the life of the engine Engine Fuel Oil Filter Oil/Water Air Cleaner il Filter Model pe © Element Separator Element — { - — 7 oe _ Direct | sy90005s600 4TNES4 129150-35151 a There are many 'Swiral ipre-combustion 129901-55850 | 171081-55910 | types; check the —__1__} part numbers. 4TNES8: t 119000-55600 4TNE106 | 119005-35100 t 4TNE106T t 1 406. TROUBLE AND TROUBLESHOO If you should encounter some difficulty during operation, refer to the following table for counter- measures Trouble Probable Cause Measure Reference 1. Alarm Lamps On [NOTICE] During Operation When the alarm lamp comes on, immediately cut off the (Trouble) load, bring the engine to a stop, and inspect. @Oil Press. Alarm Lamp | Engine L.O. insufficient | Supply engine oil 3.3 goes on. LO. filter clogged Replace L.O. filter and engine oil 5.3.1(1) @C.W.Temp.Alarm Lamp | Insufficient radiator cooling | Check cooling water and | 4.1(4) goes on. water replenish. Dirty radiator fins Clean radiator fins. 5.3.3(3) Leaky radiator cooling Ask for repairs for water water pipe leakage. V-belt is loose or broken. | Adjust or replace V-belt | 5.3.1(2) Cooling water pump is | Ask for repairs. damaged, Inside of C.W. system is Ask for repairs. dirty. @Charge Lamp V-belt is loose or broken. | Adjust or replace V-belt | 5.3.1(2) Insufficient battery charge Check battery fluid and | 5.3.2(4) charge battery. Ask for repairs, 2, Faulty Warning [NOTICE) Devices Do not operate the engine if alarm devices are not repaired. Serious accidents may result if difficulties are not spotted due to faulty alarm lamps. @When switch is turned on (OFF-*ON) Alarm lamps do not go | Circuit broken or lamp | Ask for repairs. on. burnt out. @When the key returned (START-+ON) ‘One of the alarm lamps | Sensor switches faulty. | Ask for repairs. does not go out. 4-Trouble Probable Cause Measure Reference 3. Starting Failures @Starter tums, but engine | No fuel Replenish fuel bleed. | 3.2 does not start Air in the fuel system Bleed. 3.22 Insufficient fuel Replace with recommend- | 3.1.1 ed fuel. 5.34 Clogged fue! filter Clean or replace element. Weak fuel injection sound | Ask for repairs Pressure leakage from | Ask for repairs. intake/exhaust valves @starter does not turn or | Insufficient battery charge | Check luid level «recharge + | 5.3.1(3) turns slowiy. (Engine can replace. be turned manually.) Cable terminal contact | Remove rust from termi- failure nal + retighten. Faulty starter switch device | Ask for repairs. Faulty starter Ask for repairs | Engine cannot be tuned | Internal parts seized: | Ask for repairs. manually broken. 4, Abnormal Exhaust Color @Black smoke Overload Reduce load. Air cleaner diy & clogged | Clean & replace element. | §.3.3(5) Insufficient fuel | Improper fuel Replace with recommend- | 3.1.1 ed fuel Faulty spraying of F.O. | Ask for repairs. injection valve Excessive intake/exhaust | Ask for repairs. valve head clearance @white smoke Improper fuel Replace with recommend: | 3.1.1 ed fuel. Faulty spraying of F.0. | Ask for repairs. injection valve Fuel injection timing off | Ask for repairs. Lube oil burns - exces- Ask for repairs sive consumption 2[ : Consulting Your Yanmar Dealer or Distributor Refer difficult problems and repairs to your YANMAR dealer or distributor. At the time of trouble, check and report the following. @Engine model and number (For serial number, see 2.3 [Names of Parts) @Type of auxiliary machinery being used, name of maker, model and serial number @Use, type of work, no. of hours run @Total no. of operation hours (refer to hour meter), age of machine If there is no hour meter, use number of hours per day X number of days and amount of fuel used. ®Condition immediately before trouble (engine rpm, type of operation, load condition, etc.) Details of trouble (exhaust color, sound of engine, does engine start, can engine be turned manually, type of fuel used, brand and viscosity of lube cil, etc.) @Past problems and repairs 3SS YANMAR DIESEL ENGINE CO.,LTD. OVERSEAS OPERATIONS DIVISION 1-32, CHAYAMACHI,KITA-KU,OSAKA 530-831 1, JAPAN. TEL : 81-6-376-6411 FAX : 81-6-377-1242 YANMAR DIESEL AMERICA CORP. 951 CORPORATE GROVE DRIVE, BUFFALO GROVE, IL 60089-4508, U.S.A TEL : 1-847-541-1900 FAX = 1-847-541-2161 YANMAR EUROPE B.V. BRUGPLEIN 11, 1992 BS ALMERE-DE VAART, THE NETHERLANDS P.0.8OX 301 12,1303, TEL : 31-36-5493200 FAX = 31-96-5493209 YANMAR ASIA (SINGAPORE) CORPORATION PTE LTD. 4 TUAS LANE. SHINGAPORE 638613 TEL : 65-961-3855 FAX : 65-862-5195 User's record Date of purchase Place of purchase (Name of dealer) 49961-101301 Printed in Japan