KOMATSU 4D98E, 4D108, S4D108 SERIES DIESEL ENGINE SHOP MANUAL WEBM4D9801 – PDF

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KOMATSU 4D98E, 4D108, S4D108 SERIES DIESEL ENGINE SHOP MANUAL WEBM4D9801 – PDF DOWNLOAD

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KOMATSU 4D98E, 4D108, S4D108 SERIES DIESEL ENGINE SHOP MANUAL WEBM4D9801 – PDF DOWNLOAD

Language : English
Pages : 204
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

KOMATSU 4D98E, 4D108, S4D108 SERIES DIESEL ENGINE SHOP MANUAL WEBM4D9801 – PDF DOWNLOAD

MAIN MENU...........................................................................  0
COVER...............................................................................  0
0.1 FOREWORD........................................................................  7
0.2 FOR SAFE SERVICING..............................................................  8
0.3 PRECAUTIONS FOR SAFE SERVICING..................................................  9
	(A) SERVICE SHOP (PLACE)........................................................  9
	(B) WORKING WEAR................................................................ 10
	(C) TOOLS TO BE USED............................................................ 10
	(D) USE OF GENUINE PARTS, OIL AND GREASE........................................ 10
	(E) BOLT AND NUT TIGHTENING TORQUES............................................. 10
	(F) ELECTRICAL PARTS............................................................ 11
	(G) WASTE TREATMENT............................................................. 11
	(H) HANDLING THE PRODUCT........................................................ 12
CONTENTS............................................................................ 13
1. GENERAL.......................................................................... 15
	1.1 ENGINE NOMENCLATURE......................................................... 17
	1.2 SPECIFICATIONS.............................................................. 18
	1.3 FUEL OIL, LUBRICATING OIL AND COOLING WATER................................. 22
	1.4 ENGINE EXTERNAL VIEWS....................................................... 25
	1.5 STRUCTURAL DESCRIPTION...................................................... 26
	1.6 HOW TO READ THIS MANUAL..................................................... 27
		(1) RANGE OF OPERATION EXPLANATION.......................................... 27
		(2) HOW TO READ THE EXPLANATIONS............................................ 27
		(3) DEFINITION OF TERMS..................................................... 28
		(4) ABBREVIATIONS........................................................... 28
	1.7 PRECAUTIONS FOR SERVICE WORK................................................ 29
	1.8 TIGHTENING TORQUES FOR STANDARD BOLTS AND NUTS.............................. 30
2. TROUBLESHOOTING.................................................................. 32
	2.1 QUICK REFERENCE TABLE FOR TROUBLESHOOTING................................... 34
	2.2 TROUBLESHOOTING BY MEASURING COMPRESSION PRESSURE........................... 37
		(1) COMPRESSION PRESSURE MEASUREMENT METHOD................................. 37
		(2) STANDARD COMPRESSION PRESSURE........................................... 37
		(3) ENGINE SPEED AND COMPRESSION PRESSURE................................... 38
		(4) MEASURED VALUE AND TROUBLESHOOTING...................................... 38
3. INSPECTION AND ADJUSTMENT........................................................ 39
	3.1 OIL INSPECTION.............................................................. 41
	3.2 COOLING WATER INSPECTION.................................................... 41
	3.3 INSPECTING WATER LEAK FROM COOLING WATER SYSTEM AND RADIATOR................ 41
	3.4 FAN BELT TENSION INSPECTION AND ADJUSTMENT.................................. 42
	3.5 ADJUSTING THE VALVE CLEARANCE............................................... 43
	3.6 INSPECTING THE FUEL INJECTION VALVE INJECTION PRESSURE AND SPRAY PATTERN.... 44
	3.7 FUEL INJECTION TIMING INSPECTION AND ADJUSTMENT............................. 48
	3.8 ADJUSTING THE NO-LOAD MAXIMUM (OR MINIMUM) REVOLUTIONS...................... 49
	3.9 SENSOR INSPECTION........................................................... 50
	3.10 BATTERY INSPECTION......................................................... 51
	3.11 ADJUSTING OPERATION........................................................ 53
	3.12 LONG STORAGE............................................................... 54
	3.13 PERIODIC MAINTENANCE SCHEDULE.............................................. 55
4. ENGINE BODY...................................................................... 57
	4.1 INTRODUCTION................................................................ 59
	4.2 CYLINDER HEAD............................................................... 60
		(1) COMPONENTS.............................................................. 60
		(2) DISASSEMBLY PROCEDURE................................................... 60
		(3) REASSEMBLY PROCEDURE.................................................... 61
		(4) SERVICING POINTS........................................................ 61
		(5) PARTS INSPECTION AND MEASUREMENT........................................ 63
		(6) VALVE SEAT CORRECTION................................................... 66
		(7) VALVE GUIDE REPLACEMENT................................................. 68
		(8) VALVE STEM SEAT REPLACEMENT............................................. 68
	4.3 GEAR TRAIN AND CAMSHAFT..................................................... 69
		(1) COMPONENTS.............................................................. 69
		(2) DISASSEMBLY PROCEDURE................................................... 69
		(3) REASSEMBLY PROCEDURE.................................................... 69
		(4) SERVICING POINTS........................................................ 70
		(5) PARTS INSPECTION AND MEASUREMENT........................................ 72
		(6) OIL SEAL REPLACEMENT.................................................... 74
		(7) CAMSHAFT BUSHING REPLACEMENT............................................ 74
	4.4 CYLINDER BLOCK.............................................................. 75
		(1) COMPONENTS.............................................................. 75
		(2) DISASSEMBLY PROCEDURE................................................... 75
		(3) REASSEMBLY PROCEDURE.................................................... 75
		(4) SERVICING POINTS........................................................ 76
		(5) PARTS INSPECTION AND MEASUREMENT........................................ 79
		(6) CYLINDER BORE CORRECTION................................................ 87
		(7) PISTON PIN BUSHING REPLACEMENT.......................................... 88
		(8) OIL SEAL REPLACEMENT.................................................... 88
5. LUBRICATION SYSTEM............................................................... 89
	5.1 LUBRICATION SYSTEM DIAGRAM.................................................. 91
	5.2 TROCHOID PUMP COMPONENTS.................................................... 91
	5.3 DISASSEMBLY (REVERSE THE PROCEDURE BELOW FOR ASSEMBLY)...................... 92
	5.4 SERVICING POINTS............................................................ 92
	5.5 PARTS INSPECTION AND MEASUREMENT............................................ 92
6. COOLING SYSTEM................................................................... 93
	6.1 COOLING WATER SYSTEM........................................................ 95
	6.2 COOLING WATER PUMP COMPONENTS............................................... 95
	6.3 DISASSEMBLY (REVERSE THE PROCEDURE BELOW FOR ASSEMBLY)...................... 96
	6.4 SERVICING POINTS............................................................ 96
7. FUEL INJECTION PUMP/GOVERNOR..................................................... 97
	7.1 INTRODUCTION................................................................ 99
	7.2 FUEL INJECTION PUMP......................................................... 99
		(1) FUEL SYSTEM DIAGRAM..................................................... 99
		(2) COMPONENTS..............................................................100
		(3) DISASSEMBLY PROCEDURE...................................................100
		(4) ASSEMBLY PROCEDURE......................................................101
		(5) SERVICING POINTS........................................................101
		(6) PARTS INSPECTION AND MEASUREMENT........................................103
	7.3 FUEL INJECTION VALVE........................................................105
	7.4 FUEL FEED PUMP..............................................................105
		(1) COMPONENTS..............................................................105
		(2) DISASSEMBLY PROCEDURE...................................................105
		(3) PARTS INSPECTION AND MEASUREMENT........................................105
	7.5 GOVERNOR....................................................................106
		(1) COMPONENTS..............................................................106
		(2) DISASSEMBLY PROCEDURE...................................................106
		(3) PARTS INSPECTION AND MEASUREMENT........................................106
	7.6 SPECIAL SERVICE TOOLS FOR DISASSEMBLY/ASSEMBLY..............................107
8. TURBOCHARGER (FOR 4TNE106T)......................................................109
	8.1 STRUCTURE AND FUNCTIONS.....................................................111
		(1) STRUCTURAL AND FUNCTIONAL OUTLINE.......................................111
		(2) STRUCTURE...............................................................112
		(3) COMPONENTS..............................................................113
	8.2 SERVICE STANDARDS...........................................................114
		(1) SERVICE STANDARDS.......................................................114
		(2) TIGHTENING TORQUE.......................................................114
	8.3 PERIODIC INSPECTION PROCEDURE...............................................115
		(1) PERIODIC INSPECTION INTERVALS...........................................115
		(2) INSPECTION PROCEDURE....................................................115
		(3) WASTE GATE VALVE ADJUSTMENT PROCEDURE...................................116
	8.4 DISASSEMBLY PROCEDURE.......................................................118
		(1) PREPARATION FOR DISASSEMBLY.............................................118
		(2) INSPECTION BEFORE DISASSEMBLY...........................................119
		(3) DISASSEMBLY.............................................................119
	8.5 WASHING AND INSPECTION PROCEDURE............................................120
		(1) WASHING.................................................................120
		(2) INSPECTION PROCEDURE....................................................121
	8.6 REASSEMBLY PROCEDURE........................................................124
		(1) PREPARATION FOR REASSEMBLY..............................................124
		(2) REASSEMBLY..............................................................124
	8.7 HANDLING AFTER DISASSEMBLY AND REASSEMBLY...................................126
	8.8 TROUBLESHOOTING.............................................................127
9. STARTING MOTOR...................................................................129
	9.1 FOR 4TNE94/98...............................................................131
		9.1.1 SPECIFICATIONS........................................................131
		9.1.2 COMPONENTS............................................................132
		9.1.3 TROUBLESHOOTING.......................................................133
		9.1.4 NAMES OF PARTS AND DISASSEMBLY PROCEDURE..............................134
		9.1.5 INSPECTION AND MAINTENANCE............................................138
			(1) ARMATURE............................................................138
			(2) FIELD COIL..........................................................140
			(3) BRUSH...............................................................140
			(4) BRUSH HOLDER........................................................141
			(5) MAGNETIC SWITCH.....................................................141
			(6) PINION CLUTCH.......................................................142
		9.1.6 SERVICE STANDARDS.....................................................144
		9.1.7 ASSEMBLY..............................................................145
		9.1.8 CHARACTERISTIC TEST...................................................147
	9.2 FOR 4TNE106(T)..............................................................148
		9.2.1 SPECIFICATIONS........................................................148
		9.2.2 CONFIGURATION DRAWING.................................................148
		9.2.3 TROUBLESHOOTING.......................................................149
		9.2.4 COMPONENT NAMES AND DISASSEMBLY PROCEDURE.............................150
		9.2.5 DISASSEMBLY PROCEDURE.................................................151
		9.2.6 INSPECTION AND MAINTENANCE............................................153
			(1) ARMATURE............................................................153
			(2) FIELD COIL..........................................................155
			(3) BRUSH...............................................................155
			(4) MAGNETIC SWITCH CONTINUITY TEST.....................................156
			(5) PINION..............................................................157
			(6) BALL BEARING........................................................157
		9.2.7 ASSEMBLY..............................................................157
		9.2.8 ADJUSTMENT............................................................158
		9.2.9 SERVICE STANDARDS.....................................................159
10. ALTERNATOR......................................................................161
	10.1 FOR 4TNE94/98..............................................................163
		10.1.1 SPECIFICATIONS.......................................................163
		10.1.2 SECTIONAL VIEW.......................................................164
		10.1.3 TROUBLESHOOTING......................................................165
		10.1.4 PARTS NAMES AND DISASSEMBLY PROCEDURE................................166
		10.1.5 INSPECTION AND OVERHAUL..............................................169
			(1) DIODE...............................................................169
			(2) ROTOR...............................................................169
			(3) STATOR..............................................................170
			(4) BRUSH...............................................................171
			(5) CHECK OF IC REGULATOR...............................................171
		10.1.6 ASSEMBLY.............................................................173
		10.1.7 SERVICE STANDARDS....................................................174
		10.1.8 PERFORMANCE TEST.....................................................175
	10.2 FOR 4TNE106(T).............................................................176
		10.2.1 SPECIFICATIONS.......................................................176
		10.2.2 EXPLODED VIEW........................................................177
		10.2.3 TROUBLESHOOTING......................................................178
		10.2.24 DISASSEMBLY PROCEDURE...............................................179
		10.2.5 INSPECTION AND MAINTENANCE...........................................180
		10.2.6 REASSEMBLY PROCEDURE.................................................181
		10.2.7 PERFORMANCE TEST.....................................................182
11. SPECIAL SERVICE TOOLS...........................................................185
	11.1 SPECIAL TOOLS..............................................................187
	11.2 MEASURING INSTRUMENTS......................................................189
12. SERVICE STANDARDS...............................................................193
	12.1 ENGINE TUNING..............................................................195
	12.2 ENGINE BODY................................................................196
		(1) CYLINDER HEAD...........................................................196
		(2) GEAR TRAIN AND CAMSHAFT.................................................197
		(3) CYLINDER BLOCK..........................................................198
	12.3 LUBRICATING OIL SYSTEM (TROCHOID PUMP).....................................200
	12.4 TIGHTENING TORQUES FOR MAIN BOLTS AND NUTS.................................201

DESCRIPTION:

KOMATSU 4D98E, 4D108, S4D108 SERIES DIESEL ENGINE SHOP MANUAL WEBM4D9801 – PDF DOWNLOAD

• 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.

S.S 18/12/24