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Komatsu 4D98 Series User Manual

Komatsu 4D98 Series
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Shop
Manual
WEBM4D9801
41198 SERIES
4D 106 SERIES
S4D106 SERIES
DIESEL ENGINE
This material is proprietary to Komatsu America International Company and is not to be reproduced, used, or
disclosed except in accordance with wriien authorization from Komatsu America International Company.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make
changes or add improvements at any time without incurring any obligation to install such changes on products sold
previously.
Due to this continuous program of research and development, periodic revisions may be made to this publication.
It is recommended that customers contact their distributor for information on the latest revision.
August 1999
Copyright 1999 Komatsu
DataKom Publishing Corporation

Table of Contents

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Komatsu 4D98 Series Specifications

General IconGeneral
BrandKomatsu
Model4D98 Series
CategoryEngine
LanguageEnglish

Summary

Foreword

Precautions for Safe Servicing

Service Shop (Place) Precautions

Guidelines for ensuring safety in the service shop environment, covering ventilation, space, cleanliness, and lighting.

Working Wear and Tools Safety

Recommendations for appropriate work attire and safe tool usage to prevent accidents and damage.

Component Handling and Electrical Safety

Precautions for handling electrical parts, battery charging, and proper waste treatment procedures.

Product Handling and Safety

Safety measures for handling the product, including fuel supply, hot parts, and rotating components.

General Information

Engine Nomenclature and Specifications

Details on engine naming conventions, specifications for various models (4TNE94, 4TNE98, 4TNE106).

Fuel, Lubricating Oil, and Cooling Water

Guidelines on the types and handling of fuel, lubricating oil, and cooling water for engine operation.

Engine External Views and Structure

Illustrations and descriptions of the engine's external components and internal structural features.

Manual Reading and Service Precautions

Guidance on how to read the manual, definitions, abbreviations, and general precautions for service work.

Standard Bolt and Nut Tightening Torques

Specifications for tightening torques of standard bolts and nuts used in engine assembly.

Troubleshooting Engine Issues

Quick Reference Troubleshooting Table

A table summarizing common trouble symptoms, their causes, and corrective actions for engine performance.

Troubleshooting via Compression Pressure

Methods and standards for measuring compression pressure to diagnose engine issues.

Inspection and Adjustment Procedures

Oil and Cooling Water System Checks

Procedures for inspecting engine oil levels, cooling water levels, and checking for water leaks.

Fan Belt Tension and Valve Clearance

Instructions for inspecting and adjusting fan belt tension and engine valve clearance.

Fuel Injection System Checks

Procedures for inspecting fuel injection valve pressure and spray pattern, and fuel injection timing.

No-Load Revolutions and Sensor Checks

Guidance on adjusting no-load revolutions and inspecting various engine sensors.

Battery Inspection and Adjusting Operations

Procedures for inspecting the battery, performing adjustments, long-term storage, and maintenance schedules.

Engine Body Service

Introduction and Cylinder Head Service

Preparation for engine service and detailed procedures for cylinder head inspection and repair.

Gear Train and Camshaft Service

Procedures for disassembling, inspecting, and servicing the gear train and camshaft components.

Cylinder Block Service

Detailed instructions for disassembling, inspecting, and servicing the cylinder block and its parts.

Lubrication System Service

Lubrication System Diagram and Components

Overview of the lubrication system diagram and identification of trochoid pump components.

Disassembly and Servicing Points

Procedures for disassembling the lubrication system and specific servicing points for key parts.

Cooling System Service

Cooling Water System and Pump Components

Diagram of the cooling water system and identification of cooling water pump components.

Disassembly and Servicing Points

Procedures for cooling system disassembly and servicing points for pump and thermostat.

Fuel Injection Pump and Governor Service

Fuel Injection Pump Procedures

Introduction, fuel system diagram, components, disassembly, and servicing for the fuel injection pump.

Fuel Injection Valve and Feed Pump

Procedures for servicing the fuel injection valve and the fuel feed pump.

Governor Service and Special Tools

Components, disassembly, and servicing for the governor, plus special tools required.

Turbocharger Service (4TNE106T)

Structure, Functions, and Standards

Overview of turbocharger structure, functions, service standards, and tightening torques.

Periodic Inspection and Procedures

Guidelines for periodic inspection intervals, procedures, waste gate adjustment, and disassembly.

Washing, Reassembly, and Troubleshooting

Procedures for washing, reassembling the turbocharger, handling after service, and troubleshooting common issues.

Starting Motor Service

Starting Motor Specifications and Components

Specifications and component details for starting motors for 4TNE94/98 and 4TNE106(T) engines.

Troubleshooting and Disassembly Procedures

Troubleshooting guide and step-by-step disassembly instructions for starting motors.

Inspection, Maintenance, and Assembly

Procedures for inspecting, maintaining, assembling, and adjusting starting motor components.

Alternator Service

Alternator Specifications and Troubleshooting

Specifications and troubleshooting flowcharts for alternators used with 4TNE94/98 and 4TNE106(T) engines.

Disassembly, Inspection, and Reassembly

Detailed procedures for alternator disassembly, component inspection, and reassembly.

Performance Testing and Service Standards

Guidelines for performing alternator performance tests and service standards for key characteristics.

Special Service Tools

Special Tools for Engine Service

List and illustrations of special tools required for engine disassembly and repair.

Measuring Instruments for Service

List and illustrations of essential measuring instruments used for engine inspection and service.

Service Standards Reference

Engine Tuning Standards

Reference table for engine tuning parameters including gaps, pressures, and temperatures.

Engine Body Component Standards

Service standards and limits for cylinder head, valve train, gear train, and cylinder block components.

Crankshaft, Piston, and Bearing Standards

Service standards for crankshaft, piston, rings, connecting rod, tappet, and related components.

Tightening Torques for Main Bolts

Specifications for tightening torques of main engine bolts and nuts, including lubrication application notes.

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