SM197T

SERVICE MANUAL 4D94E-BE4

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

4D94(L)E
4D98E

WARNING
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.

REVISED: FEBRUARY 2009

1. 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 of 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

MPa 12.3-13.3
Fuel injection pressure
{kgf/cm' } {125 -135}

Ignition order - 1-3-4-2 (No.1 cylinder on flywheel side)

Power take off - Flywheel

Direction of rotation - Counterclockwise (viewed from flywheel)

Cooling system - Radiator

Lubrication system - Forced lubrication with trochoid pump

Starting system - Electric

Diesel oil-ISO 8217 DMA, BS 2869 A1 or A2

Applicable fuel -
(cetane No. 45 min.)

Applicable lubricant - API grade class CC 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 mm 700 (fan - flywheel)

Engine dimensions Overall width mm 508 (fuel filter - alternator)

Overall height mm 706 (oil pan - rocker cover upper surface)

Dry engine weight kg 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
1. 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)

E
-"" '" z
60 600

50 500

Q)
40 400 =>
0-

0
30 300 I-

20 200
Torque
! --... 10 100
~
147Nm{15kg!. mJ/160orpmj

0 0
0.. ;;: rfJ
:I: -"" 0..

100 100
70
90 90

80 60 80

70 70
50

60 60
33 . 8kW{45 . 4H~/2450rpm
=> 40
"- 50 50 '\.
l..--- ~
=> rfJ 3: 0..
0 0.. -"" :I:

---- ---
40 30 40
\
"'" "'" "'" c
0

\)~\~ 1\ 290
30 30 210 "-
20 .....- 210 E

/
/ I\
280 =>
C/)
c
20 20 200 200
consump~J
270 0

10
10
10
/
Fuel \ 190 260 190
u

Q)

800 1.000 1.200 1.400 1.600 1.800 2,000 2,200 2,400 2,600
\ 180
250
=>
LL

Engine speed(rpm) HJZ06160

1-4 4D92E,4D94LE,4D98E
 1. GENERAL

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 Nm {18.2 kgfom}/1 ,500 rpm (Net)

E
'"
-'"' z

60 600

50 500

OJ
40 400 ::J
0-

0
30 300 I-
178. 5Nm{18. 2kgf. m}/1500rpm

\ Torque
20 200
-.....
~ 10 100

0.. 3:: en
:I: -'"' 0..

100 100
70
90 90

80 60 80

70 70
50 44kW{59HP}/2450rpm

60 60
"""-!I..
40 V '\
::J
0. 50 50 /
\J~V
en 0..
::J
'"
0
40 30 40 1\ "'-
0..

'"
-'"'
"'-
'"
:I:
"'-
'" c

30
20
30
V
./
V \\ 210
290
210
0

0.
E

20 20 ..- /'"
V / 200
280

200
::J
rn
c
270
l-/
0
0
10 Fuel consumpt i ~
~

-r
10 10 190 260
190 OJ
'---.. ::J
LL
250
0 0 0 180
800 1.000 1.200 1.400 1.600 1.800 2.000 2.200 2.400 2.600

Engine speed (rpm) HJZ06161

4D92E,4D94LE,4D98E 1-5
1. 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 kgfo m}/1, 700 rpm (Net)

E
-'" '" z

60 600

50 500

OJ
40 400
215.7Nm{22kgf. ml/1700rpm '"c-
\ o
30 300 f-

I
\
'Torque

-- 1'\
20

10
200

100

0 0
"- 3< (f)
:I: "-
100 100
70
90 90

80 60 80
48. 9kW{65. 7H~/2400rpm

70
50
70
~
\ ,
60 60 / '\
'"
0. 50
40
50 0/Y \
'"
0
40 30 40
/ 1\
(f)
"-
"-
'"
3:
-'"
"-
'"
"-
:I:
"-
'" c
/ 0

30 30 / 1\ 210
290
210
0.

20 E

20 20
/ / \ 200
280
200
'"
00
c

~
270 0

10
10
10 """- .......
Fuel consumpt i ~
\ 190 260 190
u

OJ

'"
800 1.000 1.200 1.400 1.600 1.800 2.000 2.200 2.400 2.600
\ 180
250
LL

Engine speed (rPm) HJZ06162

1-6 4D92E,4D94LE,4D98E
1. GENERAL

1-4 Engine external views

4D92E194LE/98E

11 10

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
 1. GENERAL

HJZ06164

12) Crankshaft pulley

4D92E,4D94LE,4D98E 1-9
1. GENERAL

1-5 Structural description

4D92E/94LE/98E

15

10

14 13 12 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

16 11 18 19

20

23

21
22

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
1. GENERAL

1-6 How to read this manual

(1) Range of Operation Explanation
This manual explains the troubleshooting, installation/removal, replacement, disassembly/reassembly,
inspection, adjustment and adjusting operation procedures for the engine.
Refer to the manufacturer's manual for each of the fuel injection pump, governor, starting motor and alterna-
tor except for their installation.

(2) How to Read the Explanations

(2-1) An exploded view, sectional views, a system diagram, etc. are shown at the beginning of each section
as required for easy understanding of the mounted states of the components .
(2-2) For the removal/installation of each part, the procedure is shown with the procedural step No. in the
illustration.
(2-3) Precautions and key points for disassembly and reassembly of parts are described as Points. In the
explanation for each point, detailed operation method, information, standard and precautions are
described.

Description Example

Illustration

HJZ06167

a The job contents are described in the disassembly procedure for Nos. not shown in the illustration.

Disassembly procedure Operation Points

(1) Follow steps (1) to (12) of the cylinder head Disassemble: Service point for removal
disassembly procedure. Reassemble : Service point for installation
(2) Remove the cooling water pump. Disassemble-Reassemble : Service point
(3) Remove the crankshaft pulley. (Point 1) required in both removal and installation.

t
Operation point to be explained on a later page.

1-12 4D92E,4D94LE,4D98E
 1. GENERAL

Contents omitted in this manual

Though the following jobs are omitted in the explanation in this manual, they shold be conducted in
actual work:
(1) Jacking up and lifting
(2) Cleaning and washing of removed parts as required
(3) Visual inspection

(3) Definition of Terms

k Instruction whose negligence is very likely to cause an accident. Always observe it.
Standard: Allowable range for inspection and adjustment.
Limit: The maximum or minimum value that must be satisfied during inspection or adjustment.

(4) Abbreviations

Abbreviation Meaning

Ass'y assembly

Sub-Ass'y sub-assembly

AT D.C. after top dead center

B.TD.C. before top dead center

STD Standard

IN Intake

EX Exhaust

TD.C top dead center

B.D.C bottom dead center

as oversize

US undersize

rpm revolutions per minute

HP output (horsepower)

3 Bolt/nut tightening torque

4D92E,4D94LE,4D98E 1-13
1. GENERAL

1-7 Precautions for service work

(1) Precautions for Safety
Read the safety precautions given at the beginning of this manual carefully and always mind safety in work.

(2) Preparation for Service Work

Preparation is necessary for accurate, efficient service work. Check the customer ledger file for the history
of the engine.
(2-1) Preceding service date
(2-2) Period/operation hours after preceding service
(2-3) Problems and actions in preceding service
(2-4) Replacement parts expected to be required for service
(2-5) Recording form/check sheet required for service

(3) Preparation before Disassembly

(3-1) Prepare general tools, special service tools, measuring instruments, oil, grease, non-reusable parts,
and parts expected to be required for replacement.
(3-2) When disassembling complicated portions, put matchmarks and other marks at places not adversely
affecting the function for easy reassembly.

(4) Precautions in Disassembly

(4-1) Each time a parts is removed, check the part installed state, deformation, damage, roughening,
surface defect, etc.
(4-2) Arrange the removed parts orderly with clear distinction between those to be replaced and those to be
used again.
(4-3) Parts to be used again shall be washed and cleaned sufficiently.
(4-4) Select especially clean locations and use clean tools for disassembly of hydraulic units such as the
fuel injection pump.

(5) Precautions for Inspection and Measurement

(5-1) Inspect and measure parts to be used again as required to determine whether they are reusable or
not.

(6) Precautions for Reassembly

(6-1) Reassemble correct parts in correct order according to the specified standards (tightening torques,
and adjustment standards). Apply oil to important bolts and nuts before tightening when specified .
(6-2) Always use genuine parts for replacement.
(6-3) Always use new oil seals, O-rings, packings and cotter pins.
(6-4) Apply sealant to packings depending on the place where they are used. Apply oil or grease to sliding
contact portions, and apply grease to oil seal lips.

(7) Precautions for Adjustment and Check

(7-1) Use measuring instruments for adjustment to the specified service standards.

1-14 4D92E,4D94LE,4D98E
 1. GENERAL

1-8 Tightening torques for standard bolts and nuts

(Lubricating oil not applied)
(Unit: Nm {kgfom})

Nominal thread
Item Tightening torque Remarks
diameter x pitch

M6 x 1 9.8 -11 .8 {1.0 -1 .2}
M8 x 1.25 22.5 - 28.4 {2.3 - 2.9}
Hexagon bolt (IT)/nut
M10 x 1.5 44.1 - 53.9 {4.5 - 5.5}
1) Use 80% of the value at left when
the tightening side is aluminum.
2) Use 60% of the value at left for 4 T
bolts and lock nuts.

M12x1.75 78.4 - 98 {8.0 - 10}

1/8 9.8 {1 .0}

1/4 19.6 {2.0}

PT plug
3/8 29.4 {3.0}

1/2 58.8 {6.0}

M8 12.7 - 16.7 {1.3 - 1.7}

M12 24.5 - 34.3 {2.5 - 3.5}

Pipe joint bolt
M14 39.2 - 49 {4.0 - 5.0}

M16 49 - 58.8 {5.0 - 6.0}

4D92E,4D94LE,4D98E 1-15