Komatsu 4D98 Series Install guide

Shop
Manual
WEBM4D9801
41198SERIES
4D106 SERIES
S4D106SERIES
DIESEL ENGINE
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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
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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

Publication No. HINSHI-H8013-Rl
History of Correction Page No. 1
rllanual Name: Yanmer Service Manual for Industrial Diesel Engine
EngineModel: Model 4TNE94.98.106(T) (Direct Injection System)
dumber of Cause for Outline of correction Corrected Corrected
:orrection Data of correction correction item number by:
Rev. 1 Mar. 2, 1998
Addition of model 4TNE106(T) with the publication No. changed to HINSHI-H8013-Rl

0.1 FOREWORD ..................................................................... O-l
0.2 FOR SAFE SERVICING .................................................... o-2
0.3 PRECAUTIONS FOR SAFE SERVICING ......................... O-3
(4
(w
G)
(D)
(E)
u=)
(G)
0-u
Service Shop (Place) ................................................ o-3
Working Wear ........................................................... o-4
Tools to Be Used ....................................................... o-4
Use of Genuine Parts, Oil and Grease.. .................... O-4
Bolt and Nut Tightening Torques .............................. o-4
Electrical Parts .......................................................... O-5
Waste Treatment.. ..................................................... O-5
Handling the Product ................................................. O-6

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 explana-
tion in this manual assumes the standard type engine, the specifications and components may par-
tially 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 de-
tails.
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.
This propduct has been developed, desigened and manufactured
in a plant certified by the JMI, BSI and EQNET to conform to the
quality assurance system standard provided as IS0 9001
(International Standard for Quality Assurance).
o-1

A For Safe Servicing
Most accidents are caused by negligence of basic safety rules and precautions. For accident
prevention, it is important to avoid such causes before development to accidents.
Please read this manual carefully before starting repair or maintenance to fully understand safety
precautions and appropriate inspection and maintenance procedures.
Attempting at a repair or maintenance job without sufficient knowledge may cause an unexpected
accident.
It is impossible to cover every possible danger in repair or maintenance in the manual. Sufficient
consideration for safety is required in addition to the matters marked A CAUTION. Especially for
safety precautions in a repair or maintenance job not described in this manual, receive instructions
from a knowledgeable leader.
Safety marks used in this manual and their meanings are as follows:
A DANGER
A WARNING
A CAUTION
DANGER-indicates an imminently hazardous situation which, if not
avoided, WILL result in death or serious injury.
WARNING-indicates a potentially hazardous situation which, if not
avoided, COULD result in death or serious injury.
CAUTION-indicates a potentially hazardous situation which, if not
avoided, may result in minor or moderate injury.
Any matter marked [NOTICE] in this manual is especially important in servicing. If not observed,
the product performance and quality may not be guaranteed.
o-2

Precautions for Safe Servicing
(A) Service Shop (Place)
(WARNING)
l Place allowing sufficient ventilation
Jobs such as engine running, part welding and polishing the
paint with sandpaper should be done in a well-ventilated place.
[Otherwise]
Very dangerous for human body due to the possibility of
poisonous gas or dust inhalation.
(a_) l Sufficiently wide and flat place
The floor space of the service shop for inspection and mainte-
nance shall be sufficiently wide and flat without any hole.
[Otherwise]
An accident such as a violent fall may be caused.
l Clean, orderly arranged place
No dust, mud, oil or parts shall left uncleaned on the floor sur-
face.
[Otherwise]
An unexpected accident may be caused.
Bright, safely illuminated place
The working place should be illuminated sufficiently and safely.
For a job in a dark position involving difficulty in observation,
use a portable safety lamp. The bulb shall be covered with a
wire cage.
[Otherwise]
The bulb may be broken accidentally to cause ignition of
leaking oil.
/ [cnuTloN] l
d
+
I
Place equipped with a fire extinguisher
Keep a fast aid kit and fire extinguisher close at hand in prepa-
ration for an emergency of fire starting.
o-3

(B) Working Wear
l Wears for Safe Operation
Wear a helmet, working clothes, safety shoes and other safety
protectors matching each job. Especially, wear well-fitting
working clothes.
[Otherwise]
A serious accident such as trapping by a machine may
arise.
(C) Tools to Be Used
l Appropriate holding and lifting
Never operate when the engine is supported with blocks or
wooden pieces or only with a jack. To lift and hold the engine,
always use a crane with a sufficient allowance in limit load or a
rigid jack.
[Otherwise]
A serious accident may arise.
l Use of Appropriate Tools
Use tools matching the jobs to be done. Use a correctly sized
tool for loosening or tightening a machine part.
[Otherwise]
A serious injury or engine damage may arise.
(D) Use of Genuine Parts, Oil and Grease
l Always use genuine parts.
Shortening of engine life or an unexpected accident may
(E) Bolt and Nut Tightening Torques
f [WnRNlNG)
l Always tighten to the specified torque if designated in the
manua, .
[Otherwise]
Loosening or falling may cause parts damage or an injury.
o-4

(F) Electrical Parts
l Harness Short-circuit
Disconnect the battery negative (-) terminal before starting the
service job.
[Otherwise]
Shorting of a harness may occur to start a fire.
’ (a] l BatteryCharging
Since flammable gas is generated during battery charging,
keep any fire source away.
[Otherwise]
Explosion may arise.
1 [A WARNING ) * Battery Electrolyte
Since the electrolyte is diluted sulfuric acid, do not let it be
splashed onto clothes or skin.
[Otherwise]
The clothes or skin may be burnt.
(G) Waste Treatment
Observe the following instructions with regard to waste disposa
Negligence of each instruction will cause environmental pollution.
l Waste fluids such as engine oil and cooling water shall be dis-
charged into a container without spillage onto the ground.
l Do not let waste fluids be discharged into the sewerage, a river
or the sea.
l Harmful wastes such as oil, fuel, solvents, filter elements and
battery shall be treated according to the respective laws and
regulations. Ask a qualified collecting company for example.
o-5

(H) Handling the Product
l Supplying the Fuel
, a
When supplying the fuel, always keep any fire source like a
cigarette or match away.
f / / [Otherwise]
A fire or explosion may arise.
[A WARNING ] l Pay attention to hot portions.
Do not touch the engine during running or immediately after it
is stopped.
[Otherwise]
Scalding may be caused by a high temperature.
l Pay attention to the rotating part.
Never bring clothes or a tool close to the rotating part during
rngine running.
[Otherwise]
Injury may be caused by entrapping.
O-6

CONTENTS
1.
2.
3.
4.
5.
6.
7.
8.
9.
9.1
GENERAL ............................................................... 1-1-1-13
TROUBLESHOOTING ............................................ 2-l-2-6
INSPECTION AND ADJUSTMENT ......................... 3-l -3-l 5
ENGINE BODY ....................................................... 4-l-4-30
LUBRICATION SYSTEM ........................................ 5-I-5-2
COOLING SYSTEM ................................................ 6-1-6-2
FUEL INJECTION SYSTEM/GOVERNOR .............. 7-1-7-9
TURBOCHARGER (FOR 4TNElO6T) ..................... 8-l -8-l 8
STARTING MOTOR ................................................ 9-1-9-29
For 4TNE94/98 ............................*........................... 9-l -9-l 7
9.2 For 4TNEl06(T) ...................................................... 9-18-9-29
10. ALTERNATOR ........................................................ 10-l-10-21
10.1 For 4TNE94/98 ................................................. 1o-1-1 o-13
10.2 For 4TNE106(T) ................................................ 1O-14-1 O-21
11. SPECIAL SERVICE TOOLS ................................... 11-l-11-5
12. SERVICE STANDARDS ..*...................................... 12-1-12-7

1. GENERAL ............I..................... 1-1-1-13
1.1 ENGINE NOMENCLATURE .............................................. 1-I
1.2 SPECIFICATIONS ............................................................ l-2
1.3 FUEL OIL, LUBRICATING OIL
AND COOLING WATER ................................................... 1-6
1.4 ENGINE EXTERNAL VIEWS ............................................ 1-8
1.5 STRUCTURAL DESCRIPTION ......................................... 1-9
1.6 HOW TO READ THIS MANUAL ...................................... I-10
(1) Range of Operation Explanation ........ .. . .. .. .. .. . .. .. . .. .. 1-l 0
(2) How to Read The Explanations ............................... l-10
(3) Definition of Terms .................................................. 1-I 1
(4) Abbreviations .......................................................... 1-I 1
1.7 PRECAUTIONS FOR SERVICE WORK.. ....................... I-1 2
1.8 TIGHTENING TORQUES FOR
STANDARD BOLTS AND NUTS ..................................... I-13

1. General
1.I Engine Nomenclature
4 TNE ~00-00
None: Natural aspirated engine
Cylinder bore (in mm)
Model series
Number of cylinders
l Engine application class
Application Revolving speed Number of revolutions (rpm) I
1Generator drivina 1 Constant weed 1 1500/l 800
I CL
1 VM ) General purpose Variable speed
%The engine application class (CL or VM) is described in the specifications table.
l-l

f. General
1.2 Specifications
(1) 4TNE94
Engine name 1 Unit 1 4TNE94 I
Engine specification class I - I CL I VM I
Tfle I - I Vertical, in-line, 4-cycle, water-cooled diesel
engine
Combustion chamber I - I Direct injection I
Number of cylinders
Cylinder bore x stroke
4
mm xmm 94x100
Displacement Ie I 2.776 I
Continuous
rating Revolving speed
output rpm 1500 1800
26.1 31.3
(35.0) (42.0)
Rated output Revolving speed
output
Fuel injection timing (FID, bTDC)
rpm
;,
deg
1500 1800 2000 2200 2400 2500
29.1 (Z) (Z) (Z) 41.6 43.0
(39.0) (55.8) (57.7)
10-12
Fuel injection pressure MPa
(kof/cmY 21.57- 22.55
(220-230) I
Ignition order I- I l-3-4-2 (No. 1 cylinder on flywheel side) I
Power take off
Direction of rotation
Flywheel
Counterclockwise (viewed from flvwheel)
Cooling system I- I. Radiator I
Lubrication system I- I Forced lubrication with trochoid pump I
Engine dimensions
l-2

1. General
(2) 4TNE98
Engine name 1 Unit I 4TNE98
Engine specification class
Type
Combustion chamber
CL VM
Vertical, in-line, 4-cycle, water-cooled diesel
engine
Direct iniection
Number of cylinders I - I 4
Cylinder bore x stroke /mm xmm j 98x110
Displacement e 3.319
Continuous Revolving speed rpm 1500 1800
rating output ;; 30.9 36.8
(41.4) (49.3)
Rated output Revolving speed rpm 1500 1800 2000 ) 2200 / 2400 j 2500
Fuel injection timing (FID, bTDC) 1 deg 10-12
Fuel injection pressure 21.57- 22.55
(220-230)
Ignition order I- I l-34-2 (No. 1 cylinder on flywheel side)
Power take off
Direction of rotation
Flywheel
Counterclockwise (viewed from flvwheel)
Cooling system I- I Radiator
Lubrication system I- I Forced lubrication with trochoid pump
Starting svstem Electric
Applicable fuel
Applicable lubricant
Diesel oil-IS0 8217 DMA, BS 2869 Al or A2
(cetane No. 45 min.)
API grade class CD
Battery capacity / V-AH I 12-64 (5HR) or above
Lubricant capacity Total e 10.2
oil pan) Effective e 4.5
Cooling water capacity (engine only) / 4.2
Engine dimensions Overall length mm 720
Overall width mm 508
Overall height mm 689
Engine weight (dry) kg 223
1-3

1. General
(3)4TNE106
Engine specification class
Type
CL VM
Vertical, in-line, 4-cycle, water-cooled diesel
engine
Combustion chamber Direct injection
Number of cvlinders 4
Cylinder bore x stroke /mm xmm / 106x 125
Displacement Ie I 4.412
Continuous Revolving speed
rating output
Rated output Revolving speed
output
Fuel injection timing (FID, bTDC)
1500 1800
(Z) (K)
1500 1800 2000 2200 2400 2500
49.3 58.8 56.6 61.4 65.5 67.7
(66.1) (78.8) (75.8) (82.3) (87.8) (90.7)
13-15
Fuel injection pressure 21.57- 22.55
(220-230)
Ignition order I- I i-3-4-2 (No. 1 cylinder on flywheel side)
Power take off
Direction of rotation
Flywheel
Counterclockwise (viewed from flywheel)
Cooling system I- I Radiator
Lubrication system I- I Forced lubrication with trochoid pump
Starting svstem I - 1 ~____ Electric
Applicable fuel I - Diesel oil-IS0 8217 DMA, BS 2869 Al or A2
(cetane No. 45 min.)
Applicable lubricant I- I API grade class CD
Battery capacity ) V-AH I 12-88 (5HR) or above
Lubricant capacity Total e 12.5
(oil pan) Effective e 5.5
Cooling water capacity (engine only) ( 6.0
Engine dimensions Overall length mm 789
Overall width mm 535
1Overall height I mm 750
Engine weight (dry) kg 301
1-4

1. General
(4) 4TNE106T
Engine name
Engine specification class
Type
Combustion chamber
Unit 4TNE106T
CL VM
Vertical, in-line, 4-cycle, water-cooled diesel
engine
Direct iniection
Number of cylinders 4
Cylinder bore x stroke mm xmm 106 x 125
Displacement e 4.412
Continuous Revolving speed rpm 1500 1800
rating output kW 54.8 65.5 -
Rated output Revolving speed
output
Fuel injection timing (FID, bTDC)
(hp)
rpm
0
deo
(73.4) (87.8)
1500 1800 2000 2200 2400 2500
60.3 72.1 69.9 75.8 81.6 84.2
(80.8) (96.6) (93.7) (101.6) (109.3) (112.8)
11-13
Fuel injection pressure
Ignition order
Power take off
MPa
(kgf/cm’) 21.57- 22.55
(220-230)
l-3-4-2 (No. 1 cylinder on flywheel side)
Flvwhenl
Direction of rotation Counterclockwise (viewed from flywheel)
Cooling system Radiator
Lubrication system Forced lubrication with trochoid pump
Starting system Electric
Applicable fuel
I
Diesel oil-IS0 8217 DMA. BS 2869 Al or A2
Applicable lubricant / (cetane No. 45 min.)
API arade class CD
Battery capacity V-AH 12-88 (5HR) or above
Lubricant capacity Total e 12.5
(oil pan) Effective e 5.5
Cooling water capacity (engine only) & 6.0
Engine dimensions Overall length mm 789
Overall width mm 547
Overall height mm 855
Engine weight (dry) kg 306
l-5

1. General
1.3 Fuel Oil, Lubricating Oil and Cooling Water
(1) Fuel oil
[NOTICE]
Useof other than the specified fuel oil may fail to obtain the full engine performance
or cause parts failures.
l Applicable fuel
Always use diesel gas oil IS0 8217DMA, BS 2869Al or A2 (cetane No. 45 min.) that is most
suitable for desired engine performance.
(2) Lubricating oil
r
[NOTICE]
Useof other than the specified lubricating oil may cause inner parts seizure or early
wear, leading to shortening of the engine service life.
l Applicable lubricating oil
Use lubricating oil of CD class of API
Service Classification.
Select the viscosity number according to
the ambient temperature by referring to
the table below.
l Handling of lubricating oil
1)
2)
Carefully store and handle the oil so
as to prevent dust or dirt entrance.
When supplying the oil, pay careful
attention and clean around the filler
port.
Do not use mixture of different types
of oil as it may degrade the lubricat-
ing performance.
Selection of viscosity
(SAE Service grade)
Atmospheric temperature (“C)
15W-40/1OW-30can be used
almost throuohout the year.
1
l-6

1. General
(3) Cooling water
Use clean drinkable water (tap water or rainwater) as the cooling water.
- [NOTICE]
Always add antirust or antifreeze in the cooling water.
Especially in cold weather, be sure to add antifreeze to prevent freezing. Since scale
or rust will be generated in the water piping when only clear water is used, the cool-
ing performance is worsened. In a cold weather, the cooling water may be expanded
by freezing to cause damage to the cooling system parts.
1)
2)
Rust preventive agent
Be sure to add the rust preventive agent
to the cooling water. However, do not
use it in cold weather because freezing
will occur.
When you use a rust preventive agent
sold on the market, be sure to follow the
mixing rate designated by the manufac-
turer.
Replace the rust preventive agent once
a year.
Antifreeze
In cold weather, be sure to add the anti-
freeze to prevent freezing.
If you use antifreeze, addition of the rust
preventive agent is unnecessary. Anti-
freeze can be used throughout the year.
The mixing rate should be between 30%
and 55%.
Lowest atmospheric
temperature “C j -45;; ( -20 1 -25
I
Mixing rate % 1 30 / 35 / 40
[NOTICE]
Excessive addition of antifreeze will
worsen engine cooling.
Always observe the mixing rate speci-
fied by the manufacturer for each am-
bien t temperature.
When you use an antifreeze sold on the market, be
sure to follow the mixing rate designated by the
manufacturer.
Replace the antifreeze once a year.
l-7

1. General
1.4 Engine External Views
Exhaust manifold Cylinder head
Sonnet Intake manifold
I /
Starting
I Flywheel housing
I- / Gear case cover
Fuel injection valve Gear /case
Fuel injection pump Cooling water inlet
I
Stop motor r I
Fuel filter
\ Governor I Radiator fan
Cooling water outlet /
Oil p/an I
Dipstick Ludricating Fuel feed pump
oil filter
Cooling water pump Alternator
l-8

21 Nozzle I
IO Cplimtzed nozzle hole
I
l Walers-box
diecasl
of clearance
l Reduction of slapping /
0 Semi.open deck
structure
3 Reduced number of
drilled holes for lubricant
bf pi\l I* Cold roll steel type 1
\
22 1Low-noise kll 1
I
17 Filler Installation
l 011 cooler provided
as an option
I ,
body size ’
- Adaptation lo low
speed operalion
Simpler structure
I/*
Reducllon of drilled holes
I’
Noise reducllon