KOMATSU 94E-98E SERIES DIESEL ENGINE SERVICE REPAIR MANUAL (SEBM013001) KOMATSU 94E-98E SERIES – PDF DOWNLOAD

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KOMATSU 94E-98E SERIES DIESEL ENGINE SERVICE REPAIR MANUAL (SEBM013001) KOMATSU 94E-98E SERIES

KOMATSU 94E-98E SERIES DIESEL ENGINE SERVICE REPAIR MANUAL (SEBM013001) KOMATSU 94E-98E SERIES – PDF DOWNLOAD:

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KOMATSU 94E-98E SERIES DIESEL ENGINE SERVICE REPAIR MANUAL (SEBM013001) KOMATSU 94E-98E SERIES

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 4D94/98 engine. Refer to the manufacturer’s manual for each of the fuel injection pump, governor, starting motor and alternator 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.

 TABLE OF CONTENTS:

KOMATSU 94E-98E SERIES DIESEL ENGINE SERVICE REPAIR MANUAL (SEBM013001) KOMATSU 94E-98E SERIES

COVER................................................................................  1
CONTENTS.............................................................................  2
1. GENERAL...........................................................................  7
	1.1 SPECIFICATIONS...............................................................  8
	1.2 FUEL OIL, LUBRICATING OIL AND COOLING WATER.................................. 10
	1.3 ENGINE EXTERNAL VIEWS........................................................ 12
	1.4 STRUCTURAL DESCRIPTION....................................................... 14
	1.5 HOW TO READ THIS MANUAL...................................................... 16
	1.6 PRECAUTIONS FOR SERVICE WORK................................................. 18
	1.7 TIGHTENING TORQUES FOR STANDARD BOLTS AND NUTS............................... 19
2. TROUBLESHOOTING................................................................... 20
	2.1 QUICK REFERENCE TABLE FOR TROUBLESHOOTING.................................... 21
	2.2 TROUBLESHOOTING BY MEASURING COMPRESSION PRESSURE............................ 25
3. INSPECTION AND ADJUSTMENT......................................................... 27
	3.1 OIL INSPECTION............................................................... 28
	3.2 COOLING WATER INSPECTION..................................................... 28
	3.3 INSPECTING WATER LEAK FROM COOLING WATER SYSTEM AND RADIATOR................. 28
	3.4 FAN BELT TENSION INSPECTION AND ADJUSTMENT................................... 29
	3.5 ADJUSTING THE VALVE CLEARANCE................................................ 30
	3.6 INSPECTING THE FUEL INJECTION NOZZLE INJECTION PRESSURE AND SPRAY PATTERN.... 31
	3.7 FUEL INJECTION TIMING INSPECTION AND ADJUSTMENT.............................. 34
	3.8 ADJUSTING THE NO-LOAD MAXIMUM (OR MINIMUM) REVOLUTIONS....................... 35
	3.9 SENSOR INSPECTION............................................................ 36
	3.10 BATTERY INSPECTION.......................................................... 37
	3.11 ADJUSTING OPERATION......................................................... 39
	3.12 LONG STORAGE................................................................ 40
	3.13 PERIODIC MAINTENANCE SCHEDULE............................................... 41
4. ENGINE BODY....................................................................... 43
	4.1 INTRODUCTION................................................................. 44
	4.2 CYLINDER HEAD................................................................ 45
	4.3 GEAR TRAIN AND CAMSHAFT...................................................... 54
	4.4 CYLINDER BLOCK............................................................... 59
5. LUBRICATION SYSTEM................................................................ 72
	5.1 LUBRICATION SYSTEM DIAGRAM................................................... 73
	5.2 TROCHOID PUMP COMPONENTS..................................................... 73
	5.3 DISASSEMBLY (REVERSE THE PROCEDURE BELOW FOR ASSEMBLY)....................... 74
	5.4 SERVICING POINTS............................................................. 74
	5.5 PARTS INSPECTION AND MEASUREMENT............................................. 75
6. COOLING SYSTEM.................................................................... 76
	6.1 COOLING WATER SYSTEM......................................................... 77
	6.2 COOLING WATER PUMP COMPONENTS................................................ 78
	6.3 DISASSEMBLY (REVERSE THE PROCEDURE BELOW FOR ASSEMBLY)....................... 78
	6.4 SERVICING POINTS............................................................. 78
7. FUEL INJECTION PUMP/GOVERNOR...................................................... 79
	7.1 INTRODUCTION................................................................. 80
	7.2 FUEL INJECTION PUMP.......................................................... 80
	7.3 FUEL INJECTION NOZZLE........................................................ 87
	7.4 FUEL FEED PUMP............................................................... 87
	7.5 GOVERNOR..................................................................... 89
	7.6 SPECIAL SERVICE TOOLS FOR DISASSEMBLY/ASSEMBLY............................... 90
8. STARTING MOTOR.................................................................... 92
	8.1 SPECIFICATIONS............................................................... 93
	8.2 COMPONENTS................................................................... 94
	8.3 TROUBLESHOOTING.............................................................. 95
	8.4 NAMES OF PARTS AND DISASSEMBLY PROCEDURE..................................... 96
	8.5 INSPECTION AND MAINTENANCE...................................................100
	8.6 SERVICE STANDARDS............................................................106
	8.7 ASSEMBLY.....................................................................107
	8.8 CHARACTERISTIC TEST..........................................................109
9. ALTERNATOR........................................................................110
	9.1 SPECIFICATIONS...............................................................111
	9.2 SECTIONAL VIEW...............................................................112
	9.3 TROUBLESHOOTING..............................................................113
	9.4 PARTS NAMES AND DISASSEMBLY PROCEDURE........................................114
	9.5 INSPECTION AN OVERHAUL.......................................................117
	9.6 ASSEMBLY.....................................................................121
	9.7 SERVICE STANDARDS............................................................122
	9.8 PERFORMANCE TEST.............................................................123
10. SPECIAL SERVICE TOOLS............................................................124
	10.1 SPECIAL TOOLS...............................................................125
	10.2 MEASURING INSTRUMENTS.......................................................127
11. SERVICE STANDARDS................................................................130
	11.1 ENGINE TUNING...............................................................131
	11.2 ENGINE BODY.................................................................132
	11.3 LUBRICATING OIL SYSTEM (TROCHOID PUMP)......................................136
	11.4 TIGHTENING TORQUES FOR MAIN PARTS...........................................137
20. EPA CERTIFIED ENGINE.............................................................139
	20.1 APPLICABLE MACHINE, SERIAL NUMBER (EPA CERTIFIED ENGINE)....................140

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