Komatsu 4D94E-1 and 4D98E-1 engine service manual

Shop Manual CEBM004900 (HINSHI-H8013Rl) SERIES DIESEL ENGINES 4D94E SERIAL NUMBERS 4D98E ALL 4D106E This material is proprietary to Komatsu America international Company and is not to be reproduced, used, or disclosed except in accordance with written 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. June 2000 Copyright 2000 Komatsu DataKom Publishing Corporation

Publication No. HINSHI-H8013-RI History of Correction Page No. 1 Aanual Name: Yanmer Service Manual for Industrial Diesel Engine ingine Model: Model 4TNE94.98.106(T) (Direct injection System) lumber of Cause for :orrection Data of correction correction Outline of correction Corrected Corrected item number by: Rev. 1 Mar. 2, 1998 Addition of model 4TNEl06(T) with the publication No. changed to HINSHI-H8013-RI

0.1 FOREWORD ..................................................................... O-l 0.2 FOR SAFE SERVICING.. .................................................. O-2 0.3 PRECAUTIONS FOR SAFE SERVICING.. ....................... O-3 (4 w CC) P) (E) F) (G) u-0 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-l

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) ’ (W) 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. l Sufficiently wide and flat place The floor space of the service shop for inspection and maintenance shall be sufficiently wide and flat without any hole. [Otherwise] An accident such as a violent fall may be caused. 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. l Bright, safely illuminated place The working place should be illuminated sufficiently and safely. For a job in a dark position involving difficulty in observation, . ’ 1, 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. l 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. [ (-j l Use of Appropriate Tools Use tools matching the jobs to be done. Use a correctly sized 1 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. [Otherwise] Shortening of engine life or an unexpected accident may arise. I (E) Bolt and Nut Tightening Torques l (a manual Always tighten to the specified torque if designated in the . [Otherwise] Loosening or falling may cause parts damage or an injury. o-4

Komatsu 4D94E-1 and 4D98E-1 engine service manual

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