Komatsu 4D98, 4D106, S4D106 Series Diesel Engine Shop Manual WEBM4D9801

Description

• Model List:
  • 4D98 Series Diesel Engine
  • 4D106 Series Diesel Engine
  • S4D106 Series Diesel Engine

• 1. MAIN MENU
• 2. COVER
• 3. FOREWORD
• 4. FOR SAFE SERVICING
• 5. PRECAUTIONS FOR SAFE SERVICING
• 5.1. (A) SERVICE SHOP (PLACE)
• 5.2. (B) WORKING WEAR
• 5.3. (C) TOOLS TO BE USED
• 5.4. (D) USE OF GENUINE PARTS, OIL AND GREASE
• 5.5. (E) BOLT AND NUT TIGHTENING TORQUES
• 5.6. (F) ELECTRICAL PARTS
• 5.7. (G) WASTE TREATMENT
• 5.8. (H) HANDLING THE PRODUCT
• 6. CONTENTS
• 7. GENERAL
• 7.1. ENGINE NOMENCLATURE
• 7.2. SPECIFICATIONS
• 7.3. FUEL OIL, LUBRICATING OIL AND COOLING WATER
• 7.4. ENGINE EXTERNAL VIEWS
• 7.5. STRUCTURAL DESCRIPTION
• 7.6. HOW TO READ THIS MANUAL
• 7.6.1. RANGE OF OPERATION EXPLANATION
• 7.6.2. HOW TO READ THE EXPLANATIONS
• 7.6.3. DEFINITION OF TERMS
• 7.6.4. ABBREVIATIONS
• 7.7. PRECAUTIONS FOR SERVICE WORK
• 7.8. TIGHTENING TORQUES FOR STANDARD BOLTS AND NUTS
• 8. TROUBLESHOOTING
• 8.1. QUICK REFERENCE TABLE FOR TROUBLESHOOTING
• 8.2. TROUBLESHOOTING BY MEASURING COMPRESSION PRESSURE
• 8.2.1. COMPRESSION PRESSURE MEASUREMENT METHOD
• 8.2.2. STANDARD COMPRESSION PRESSURE
• 8.2.3. ENGINE SPEED AND COMPRESSION PRESSURE
• 8.2.4. MEASURED VALUE AND TROUBLESHOOTING
• 9. INSPECTION AND ADJUSTMENT
• 9.1. OIL INSPECTION
• 9.2. COOLING WATER INSPECTION
• 9.3. INSPECTING WATER LEAK FROM COOLING WATER SYSTEM AND RADIATOR
• 9.4. FAN BELT TENSION INSPECTION AND ADJUSTMENT
• 9.5. ADJUSTING THE VALVE CLEARANCE
• 9.6. INSPECTING THE FUEL INJECTION VALVE INJECTION PRESSURE AND SPRAY PATTERN
• 9.7. FUEL INJECTION TIMING INSPECTION AND ADJUSTMENT
• 9.8. ADJUSTING THE NOLOAD MAXIMUM (OR MINIMUM) REVOLUTIONS
• 9.9. SENSOR INSPECTION
• 9.10. BATTERY INSPECTION
• 9.11. ADJUSTING OPERATION
• 9.12. LONG STORAGE
• 9.13. PERIODIC MAINTENANCE SCHEDULE
• 10. ENGINE BODY
• 10.1. INTRODUCTION
• 10.2. CYLINDER HEAD
• 10.2.1. COMPONENTS
• 10.2.2. DISASSEMBLY PROCEDURE
• 10.2.3. REASSEMBLY PROCEDURE
• 10.2.4. SERVICING POINTS
• 10.2.5. PARTS INSPECTION AND MEASUREMENT
• 10.2.6. VALVE SEAT CORRECTION
• 10.2.7. VALVE GUIDE REPLACEMENT
• 10.2.8. VALVE STEM SEAT REPLACEMENT
• 10.3. GEAR TRAIN AND CAMSHAFT
• 10.3.1. COMPONENTS
• 10.3.2. DISASSEMBLY PROCEDURE
• 10.3.3. REASSEMBLY PROCEDURE
• 10.3.4. SERVICING POINTS
• 10.3.5. PARTS INSPECTION AND MEASUREMENT
• 10.3.6. OIL SEAL REPLACEMENT
• 10.3.7. CAMSHAFT BUSHING REPLACEMENT
• 10.4. CYLINDER BLOCK
• 10.4.1. COMPONENTS
• 10.4.2. DISASSEMBLY PROCEDURE
• 10.4.3. REASSEMBLY PROCEDURE
• 10.4.4. SERVICING POINTS
• 10.4.5. PARTS INSPECTION AND MEASUREMENT
• 10.4.6. CYLINDER BORE CORRECTION
• 10.4.7. PISTON PIN BUSHING REPLACEMENT
• 10.4.8. OIL SEAL REPLACEMENT
• 11. LUBRICATION SYSTEM
• 11.1. LUBRICATION SYSTEM DIAGRAM
• 11.2. TROCHOID PUMP COMPONENTS
• 11.3. DISASSEMBLY (REVERSE THE PROCEDURE BELOW FOR ASSEMBLY)
• 11.4. SERVICING POINTS
• 11.5. PARTS INSPECTION AND MEASUREMENT
• 12. COOLING SYSTEM
• 12.1. COOLING WATER SYSTEM
• 12.2. COOLING WATER PUMP COMPONENTS
• 12.3. DISASSEMBLY (REVERSE THE PROCEDURE BELOW FOR ASSEMBLY)
• 12.4. SERVICING POINTS
• 13. FUEL INJECTION PUMP/GOVERNOR
• 13.1. INTRODUCTION
• 13.2. FUEL INJECTION PUMP
• 13.2.1. FUEL SYSTEM DIAGRAM
• 13.2.2. COMPONENTS
• 13.2.3. DISASSEMBLY PROCEDURE
• 13.2.4. ASSEMBLY PROCEDURE
• 13.2.5. SERVICING POINTS
• 13.2.6. PARTS INSPECTION AND MEASUREMENT
• 13.3. FUEL INJECTION VALVE
• 13.4. FUEL FEED PUMP
• 13.4.1. COMPONENTS
• 13.4.2. DISASSEMBLY PROCEDURE
• 13.4.3. PARTS INSPECTION AND MEASUREMENT
• 13.5. GOVERNOR
• 13.5.1. COMPONENTS
• 13.5.2. DISASSEMBLY PROCEDURE
• 13.5.3. PARTS INSPECTION AND MEASUREMENT
• 13.6. SPECIAL SERVICE TOOLS FOR DISASSEMBLY/ASSEMBLY
• 14. TURBOCHARGER (FOR 4TNE106T)
• 14.1. STRUCTURE AND FUNCTIONS
• 14.1.1. STRUCTURAL AND FUNCTIONAL OUTLINE
• 14.1.2. STRUCTURE
• 14.1.3. COMPONENTS
• 14.2. SERVICE STANDARDS
• 14.2.1. SERVICE STANDARDS
• 14.2.2. TIGHTENING TORQUE
• 14.3. PERIODIC INSPECTION PROCEDURE
• 14.3.1. PERIODIC INSPECTION INTERVALS
• 14.3.2. INSPECTION PROCEDURE
• 14.3.3. WASTE GATE VALVE ADJUSTMENT PROCEDURE
• 14.4. DISASSEMBLY PROCEDURE
• 14.4.1. PREPARATION FOR DISASSEMBLY
• 14.4.2. INSPECTION BEFORE DISASSEMBLY
• 14.4.3. DISASSEMBLY
• 14.5. WASHING AND INSPECTION PROCEDURE
• 14.5.1. WASHING
• 14.5.2. INSPECTION PROCEDURE
• 14.6. REASSEMBLY PROCEDURE
• 14.6.1. PREPARATION FOR REASSEMBLY
• 14.6.2. REASSEMBLY
• 14.7. HANDLING AFTER DISASSEMBLY AND REASSEMBLY
• 14.8. TROUBLESHOOTING
• 15. STARTING MOTOR
• 15.1. FOR 4TNE94/98
• 15.1.1. SPECIFICATIONS
• 15.1.2. COMPONENTS
• 15.1.3. TROUBLESHOOTING
• 15.1.4. NAMES OF PARTS AND DISASSEMBLY PROCEDURE
• 15.1.5. INSPECTION AND MAINTENANCE
• 15.1.5.1. ARMATURE
• 15.1.5.2. FIELD COIL
• 15.1.5.3. BRUSH
• 15.1.5.4. BRUSH HOLDER
• 15.1.5.5. MAGNETIC SWITCH
• 15.1.5.6. PINION CLUTCH
• 15.1.6. SERVICE STANDARDS
• 15.1.7. ASSEMBLY
• 15.1.8. CHARACTERISTIC TEST
• 15.2. FOR 4TNE106(T)
• 15.2.1. SPECIFICATIONS
• 15.2.2. CONFIGURATION DRAWING
• 15.2.3. TROUBLESHOOTING
• 15.2.4. COMPONENT NAMES AND DISASSEMBLY PROCEDURE
• 15.2.5. DISASSEMBLY PROCEDURE
• 15.2.6. INSPECTION AND MAINTENANCE
• 15.2.6.1. ARMATURE
• 15.2.6.2. FIELD COIL
• 15.2.6.3. BRUSH
• 15.2.6.4. MAGNETIC SWITCH CONTINUITY TEST
• 15.2.6.5. PINION
• 15.2.6.6. BALL BEARING
• 15.2.7. ASSEMBLY
• 15.2.8. ADJUSTMENT
• 15.2.9. SERVICE STANDARDS
• 16. ALTERNATOR
• 16.1. FOR 4TNE94/98
• 16.1.1. SPECIFICATIONS
• 16.1.2. SECTIONAL VIEW
• 16.1.3. TROUBLESHOOTING
• 16.1.4. PARTS NAMES AND DISASSEMBLY PROCEDURE
• 16.1.5. INSPECTION AND OVERHAUL
• 16.1.5.1. DIODE
• 16.1.5.2. ROTOR
• 16.1.5.3. STATOR
• 16.1.5.4. BRUSH
• 16.1.5.5. CHECK OF IC REGULATOR
• 16.1.6. ASSEMBLY
• 16.1.7. SERVICE STANDARDS
• 16.1.8. PERFORMANCE TEST
• 16.2. FOR 4TNE106(T)
• 16.2.1. SPECIFICATIONS
• 16.2.2. EXPLODED VIEW
• 16.2.3. TROUBLESHOOTING
• 16.2.4. DISASSEMBLY PROCEDURE
• 16.2.5. INSPECTION AND MAINTENANCE
• 16.2.6. REASSEMBLY PROCEDURE
• 16.2.7. PERFORMANCE TEST
• 17. SPECIAL SERVICE TOOLS
• 17.1. SPECIAL TOOLS
• 17.2. MEASURING INSTRUMENTS
• 18. SERVICE STANDARDS
• 18.1. ENGINE TUNING
• 18.2. ENGINE BODY
• 18.2.1. CYLINDER HEAD
• 18.2.2. GEAR TRAIN AND CAMSHAFT
• 18.2.3. CYLINDER BLOCK
• 18.3. LUBRICATING OIL SYSTEM (TROCHOID PUMP)
• 18.4. TIGHTENING TORQUES FOR MAIN BOLTS AND NUTS