Komatsu 4D98E Series 4D106 Series S4D106 Series Diesel Engine Shop Manual WEBM4D9801 – PDF DOWNLOAD

Description

Komatsu 4D98E Series 4D106 Series S4D106 Series Diesel Engine Shop Manual WEBM4D9801 – PDF DOWNLOAD

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Komatsu 4D98E Series 4D106 Series S4D106 Series Diesel Engine Shop Manual WEBM4D9801 – PDF DOWNLOAD

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 4D98E Series 4D106 Series S4D106 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

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PLEASE NOTE:

• This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
• This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
• Require some other service manual or have any queries: please WRITE to us at [email protected]

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