Komatsu 4D98, 4D106, S4D106 Series Diesel Engine Shop Manual – PDF DOWNLOAD

Description

Komatsu 4D98, 4D106, S4D106 Series Diesel Engine Shop Manual

FILE DETAILS:

Komatsu 4D98, 4D106, S4D106 Series Diesel Engine Shop Manual 

Brands: Komatsu
Equipment Type: Diesel Engine
Manuals Type: Shop Manual
Machine Model: 4D98, 4D106, S4D106 Series Diesel Engine
Serial Number: –
Book Code: WEBM4D9801
Language: English
Pages: 182
File Format: Portable Document Format (PDF)

KOMATSU 4D98, 4D106, S4D106 SERIES DIESEL ENGINE SHOP MANUAL – PDF DOWNLOAD:

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Komatsu 4D98, 4D106, S4D106 Series Diesel Engine Shop Manual 

FOREWORD: 

• This manual describes the service procedures for the 4TNE94.98.106(T) engines (direct injection) for industrial use. Please use this manual for accurate, quick and safe servicing of the said engine.
• Since the explanation in this manual assumes the standard type engine, the specifications and components may partially be different from the engine installed on individual work equipment (power generator, pump, compressor, etc.).
• Please also refer to the service manual for each work equipment for details. The specifications and components may be subject to change for improvement of the engine quality. If any modification of the contents described herein becomes necessary, it will be notified in the form of a correction information each time.

TABLE OF CONTENTS:

Komatsu 4D98, 4D106, S4D106 Series Diesel Engine Shop Manual 

MAIN MENU.............................................................................  0
FOREWORD .............................................................................  4
FOR SAFE SERVICING....................................................................  5
PRECAUTIONS FOR SAFE SERVICING........................................................  6
	(A) Service Shop (Place) .........................................................  6
	(B) Working Wear .................................................................  7
	(C) Tools to Be Used .............................................................  7
	(D) Use of Genuine Parts, Oil and Grease .........................................  7
	(E) Bolt and Nut Tightening Torques ..............................................  7
	(F) Electrical Parts .............................................................  8
	(G) Waste Treatment ..............................................................  8
	(H) Handling the Product .........................................................  9
CONTENTS ............................................................................. 10
1.  GENERAL .......................................................................... 11
	1.1 Engine Nomenclature .......................................................... 12
	1.2  Specifications .............................................................. 13
	1.3 Fuel  Oil,  Lubricating Oil  and Cooling Water ............................... 17
	1.4 Engine External Views......................................................... 19
	1.5 Structural Description........................................................ 20
	1.6 How to Read This Manual....................................................... 21
		(1) Range of Operation Explanation............................................ 21
		(2) How to Read The Explanations.............................................. 21
		(3) Definition of Terms....................................................... 22
		(4) Abbreviations............................................................. 22
	1.7 Precautions for Service Work.................................................. 23
	1.8 Tightening Torques for Standard Bolts and Nuts................................ 24
2.  TROUBLESHOOTING .................................................................. 25
	2.1 Quick Reference Table for Troubleshooting..................................... 26
	2.2 Troubleshooting by Measuring Compression Pressure ............................ 29
		(1) Compression pressure measurement method................................... 29
		(2) Standard compression pressure............................................. 29
		(3) Engine speed and compression pressure (reference)......................... 30
		(4) Measured value and troubleshooting........................................ 30
3.  INSPECTION AND  ADJUSTMENT........................................................ 31
	3.1 Oil Inspection ............................................................... 32
	3.2 Cooling Water Inspection ..................................................... 32
	3.3 Inspecting Water Leak from Cooling Water System and Radiator ................. 32
	3.4 Fan Belt Tension Inspection and Adjustment ................................... 33
	3.5 Adjusting the Valve Clearance ................................................ 34
	3.6 Inspecting the Fuel Injection Valve Injection Pressure and Spray  Pattern .... 35
	3.7 Fuel Injection Timing Inspection and Adjustment............................... 39
	3.8 Adjusting the No-load Maximum (or Minimum) Revolutions ....................... 40
	3.9 Sensor Inspection ............................................................ 41
	3.10 Battery Inspection .......................................................... 42
	3.11 Adjusting Operation ......................................................... 44
	3.12 Long Storage ................................................................ 45
	3.13 Periodic Maintenance Schedule ............................................... 46
4. ENGINE BODY ....................................................................... 47
	4.1 Introduction ................................................................. 49
	4.2 Cylinder Head ................................................................ 50
		(1) Components................................................................ 50
		(2) Disassembly procedure:.................................................... 50
		(3) Reassembly procedure:..................................................... 51
		(4) Servicing points.......................................................... 51
		(5) Parts Inspection and measurement.......................................... 53
		(6) Valve seat correction..................................................... 56
		(7) Valve guide replacement................................................... 58
		(8) Valve stem seal replacement............................................... 58
	4.3 Gear Train and Camshaft ...................................................... 59
		(1) Components................................................................ 59
		(2) Disassembly procedure:.................................................... 59
		(3) Reassembly procedure:..................................................... 59
		(4) Servicing points.......................................................... 60
		(5) Parts inspection and measurement.......................................... 62
		(6) Oil seal replacement...................................................... 64
		(7) Camshaft bushing replacement.............................................. 64
	4.4 Cylinder block................................................................ 65
		(1)  Components............................................................... 65
		(2)  Disassembly procedure.................................................... 65
		(3)  Reassembly procedure..................................................... 65
		(4)  Servicing points......................................................... 66
		(5)  Parts inspection and measurement......................................... 69
		(6)  Cylinder bore correction................................................. 77
		(7)  Piston pin bushing replacement........................................... 78
		(8)  Oil seal replacement..................................................... 78
5. LUBRICATION SYSTEM................................................................. 79
	5.1 Lubrication System Diagram ................................................... 80
	5.2 Trochoid Pump Components ..................................................... 80
	5.3 Disassembly (Reverse the procedure below for assembly) ....................... 81
	5.4 Servicing Points ............................................................. 81
	5.5 Parts Inspection and Measurement ............................................. 81
6. COOLING SYSTEM..................................................................... 82
	6.1 Cooling Water System ......................................................... 83
	6.2 Cooling Water Pump Components ................................................ 83
	6.3 Disassembly (Reverse the procedure below for assembly)........................ 84
	6.4 Servicing Points ............................................................. 84
7. FUEL  INJECTION PUMP/GOVERNOR...................................................... 85
	7.1 Introduction ................................................................. 86
	7.2 Fuel Injection Pump .......................................................... 86
		(1) Fuel system diagram....................................................... 86
		(2) Components................................................................ 87
		(3) Disassembly procedure:.................................................... 87
		(4) Assembly procedure........................................................ 88
		(5) Servicing points.......................................................... 88
		(6) Parts inspection and measurement.......................................... 90
	7.3 Fuel Injection Valve ......................................................... 92
	7.4 Fuel Feed Pump................................................................ 92
		(1) Components................................................................ 92
		(2) Disassembly procedure (Reverse the procedure below for assembly.)......... 92
		(3) Parts inspection and measurement.......................................... 92
	7.5 Governor...................................................................... 93
		(1) Components................................................................ 93
		(2) Disassembly procedure (Reverse the procedure for assembly.)............... 93
		(3) Parts inspection and measurement.......................................... 94
	7.6 Special Service Tools for Disassembly/Assembly ............................... 94
8. TURBOCHARGER  (FOR  4TNE106T) ..................................................... 95
	8.1 Structure and Functions ...................................................... 97
		(1) Structural and functional outline......................................... 97
		(2) Structure................................................................. 98
		(3) Components................................................................ 99
	8.2 Service Standards ............................................................100
		(1) Service standards.........................................................100
		(2) Tightening torque.........................................................100
	8.3 Periodic Inspection Procedure ................................................101
		(1) Periodic inspection intervals.............................................101
		(2) Inspection procedure......................................................101
		(3) Waste gate valve adjustment procedure.....................................102
	8.4 Disassembly Procedure ........................................................104
		(1) Preparation for disassembly...............................................104
		(2) Inspection before disassembly.............................................105
		(3) Disassembly...............................................................105
	8.5 Washing and Inspection procedure..............................................106
		(1) Washing...................................................................106
		(2) inspection procedure......................................................107
	8.6 Reassembly Procedure .........................................................110
		(1) Preparation for reassembly................................................110
		(2) Reassembly................................................................110
	8.7 Handling after Disassembly and Reassembly ....................................112
	8.8 Troubleshooting ..............................................................113
9.  STARTING MOTOR ...................................................................115
	9.1 FOR 4TNE94/98.................................................................117
		9.1.1 Specifications..........................................................117
		9.1.2 Components..............................................................118
		9.1.3 Troubleshooting.........................................................119
		9.1.4 Names of parts and disassembly procedure................................120
		9.1.5 Inspection and Maintenance..............................................124
			(1) Armature..............................................................124
			(2) Field coil............................................................126
			(3) Brush.................................................................126
			(4) Brush holder..........................................................127
			(5) Magnetic switch.......................................................127
			(6) Pinion clutch.........................................................128
		9.1.6 Service standards.......................................................130
		9.1.7 Assembly................................................................131
		9.1.8 Characteristic test.....................................................133
	9.2 FOR 4TNEl06(T) ...............................................................134
		9.2.1 Specifications..........................................................134
		9.2.2 Configuration drawing...................................................134
		9.2.3 Troubleshooting.........................................................135
		9.2.4 Component names and disassembly procedure...............................136
		9.2.5 Disassembly procedure...................................................137
		9.2.6 Inspection and maintenance..............................................139
			(1) Armature..............................................................139
			(2) Field coil............................................................141
			(3) Brush.................................................................141
			(4) Magnetic switch continuity test.......................................142
			(5) Pinion................................................................143
			(6) Ball bearing..........................................................143
		9.2.7 Assembly................................................................143
		9.2.8 Adjustment..............................................................144
		9.2.9 Service standards.......................................................145
10.  ALTERNATOR ......................................................................146
	10.1 For 4TNE94/98 ...............................................................147
		10.1.1 Specifications ........................................................147
		10.1.2 Section view...........................................................148
		10.1.3 Troubleshooting........................................................149
		10.1.4 Parts names and disassembly procedure .................................150
		10.1.5 Inspection and overhaul ...............................................153
			(1) Diode.................................................................153
			(2) Rotor.................................................................153
			(3) Stator................................................................154
			(4) Brush.................................................................155
			(5) Check of IC regulator.................................................155
		10.1.6 Assembly ..............................................................157
		10.1.7 Service standards .....................................................158
		10.1.8 Performance test ......................................................159
	10.2 For 4TNE106(T) ..............................................................160
		10.2.1 Specifications  (1) ...................................................160
		10.2.2 Exploded View .........................................................161
		10.2.3 Troubleshooting .......................................................162
		10.2.4 Disassembly Procedure .................................................163
		10.2.5 Inspection and Maintenance ............................................164
		10.2.6 Reassembly Procedure ..................................................165
		10.2.7 Performance Test ......................................................166
11.  SPECIAL SERVICE TOOLS............................................................168
	11.1 Special Tools ...............................................................169
	11.2 Measuring Instruments .......................................................171
12.  SERVICE STANDARDS ...............................................................174
	12.1 Engine Tuning ...............................................................175
	12.2 Engine Body .................................................................176
		(1) Cylinder head.............................................................176
		(2) Gear train and camshaft...................................................177
		(3) Cylinder block............................................................178
	12.3 Lubricating Oil System (Trochoid Pump) ......................................180
	12.4 Tightening Torques for Main Bolts and Nuts ..................................181

PLEASE NOTE:

• This is the same manual used by the DEALERSHIPS to SERVICE your vehicle.
• The manual can be all yours – Once payment is complete, you will be taken to the download page from where you can download the manual. All in 2-5 minutes time!!
• Need any other service / repair / parts manual, please feel free to contact us at heydownloadss @gmail.com . We may surprise you with a nice offer