KOMATSU 68E-88E SERIES DIESEL ENGINE SERVICE REPAIR MANUAL (SEBM011501) KOMATSU 68E-88E SERIES – PDF DOWNLOAD

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KOMATSU 68E-88E SERIES DIESEL ENGINE SERVICE REPAIR MANUAL (SEBM011501) KOMATSU 68E-88E SERIES

KOMATSU 68E-88E SERIES DIESEL ENGINE SERVICE REPAIR MANUAL (SEBM011501) KOMATSU 68E-88E SERIES – PDF DOWNLOAD:

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KOMATSU 68E-88E SERIES DIESEL ENGINE SERVICE REPAIR MANUAL (SEBM011501) KOMATSU 68E-88E SERIES

Reduction in compression pressure of the cylinder is one of major causes of an increase in blow-by gas (which causes contamination and increased consumption of lubricating oil, and other trouble) as well as the engine starting failure.The compression pressure is influenced by the following factors:
1. Degree of clearance between the piston and cylinder.
2. Degree of clearance around intake/exhaust valve seats.
3. Gas leak through the nozzle gasket or cylinder head gasket.
In addition, the compression pressure decreases as the engine parts are worn and lose durability through use of the engine for a long period.
Scratches on the cylinder or piston caused by dust or foreign matter through the soiled air cleaner element, and wear or breakage of piston ring also decrease the compression pressure.
For this reason, diagnose the engine status by measuring the compression presure.

 TABLE OF CONTENTS:

KOMATSU 68E-88E SERIES DIESEL ENGINE SERVICE REPAIR MANUAL (SEBM011501) KOMATSU 68E-88E SERIES

COVER...................................................................................................  1
CONTENTS................................................................................................  2
1. SPECIFICATIONS AND PERFORMANCE.......................................................................  7
	1.1 2D68E...........................................................................................  8
	1.2 3D68E...........................................................................................  9
	1.3 3D74E........................................................................................... 10
	1.4 3D78AE.......................................................................................... 11
	1.5 3D82AE.......................................................................................... 12
	1.6 3D82E........................................................................................... 13
	1.7 3D84E........................................................................................... 14
	1.8 3D88E........................................................................................... 15
	1.9 4D82E........................................................................................... 16
	1.10 4D84E.......................................................................................... 17
	1.11 4D88E.......................................................................................... 18
	1.12 S3D84E......................................................................................... 19
	1.13 S4D84E......................................................................................... 20
2. CROSS SECTIONAL VIEWS................................................................................ 21
	2.1 SPECIAL SWIRL PRE-COMBUSTION CHAMBER SYSTEM (INDIRECT INJECTION SYSTEM)......................... 22
	2.2 DIRECT INJECTION SYSTEM......................................................................... 24
3. COOLING WATER, LUBRICATING OIL AND FUEL OIL.......................................................... 26
	3.1 COOLING WATER................................................................................... 27
	3.2 LUBRICATING OIL................................................................................. 28
	3.3 FUEL OIL........................................................................................ 30
4. TROUBLESHOOTING...................................................................................... 32
	4.1 TROUBLE CAUSES AND REMEDIES..................................................................... 33
	4.2 TROUBLE DIAGNOSIS THROUGH MEASUREMENT OF COMPRESSION PRESSURE................................... 37
5. SPECIAL SERVICE TOOLS AND MEASURING INSTRUMENTS...................................................... 38
	5.1 SPECIAL SERVICE TOOLS........................................................................... 39
	5.2 MEASURING INSTRUMENTS........................................................................... 42
6. MEASUREMENT, INSPECTION AND ADJUSTMENT............................................................... 46
	6.1 MEASURING THE COMPRESSION PRESSURE.............................................................. 47
	6.2 ADJUSTING THE VALVE HEAD CLEARANCE.............................................................. 49
	6.3 CHECKING THE V-BELT TENSION..................................................................... 50
	6.4 MEASURING AND CHECKING THE INJECTION PRESSURE AND SPRAY PATTERNS OF THE FUEL INJECTION VALVE.... 51
	6.5 CHECKING AND ADJUSTING THE FUEL INJECTION TIMING................................................ 55
	6.6 ADJUSTING THE NO-LOAD MAXIMUM (OR MINIMUM) REVOLUTIONS.......................................... 58
	6.7 CHECKING THE COOLING WATER SYSTEM AND RADIATOR FOR WATER LEAKAGE................................ 58
	6.8 CHECKING THE BATTERY............................................................................ 59
	6.9 CHECKING THE SENSORS............................................................................ 62
	6.10 CHECKING THE OIL COOLER........................................................................ 63
	6.11 CHECKING THE PISTON COOLING NOZZLE............................................................. 64
7. MEASURING PROCEDURES, SERVICE DATA AND CORRECTIVE ACTION............................................. 65
	7.1 CYLINDER HEAD................................................................................... 66
	7.2 CYLINDER BLOCK.................................................................................. 74
	7.3 VALVE ROCKER ARM................................................................................ 78
	7.4 PISTON AND PISTON RING.......................................................................... 81
	7.5 CONNECTING ROD.................................................................................. 87
	7.6 CAMSHAFT........................................................................................ 92
	7.7 CRANKSHAFT...................................................................................... 95
	7.8 GEARS........................................................................................... 98
	7.9 TROCHOID PUMP...................................................................................100
8. DISASSEMBLY AND REASSEMBLY...........................................................................102
	8.1 DISASSEMBLY.....................................................................................103
	8.2 PRECAUTIONS BEFORE AND DURING REASSEMBLY........................................................108
9. SERVICE DATA.........................................................................................113
	9.1 CYLINDER HEAD...................................................................................114
	9.2 CYLINDER BLOCK..................................................................................115
	9.3 VALVE ROCKER ARM................................................................................115
	9.4 PISTON..........................................................................................116
	9.5 PISTON RING.....................................................................................117
	9.6 CONNECTING ROD..................................................................................118
	9.7 CAMSHAFT........................................................................................118
	9.8 CRANKSHAFT......................................................................................119
	9.9 SIDE GAP AND BACKLASH...........................................................................119
	9.10 OTHERS.........................................................................................120
10. TIGHTENING TORQUE...................................................................................121
	10.1 MAIN BOLT/NUT..................................................................................122
	10.2 STANDARD BOLT AND NUT..........................................................................123
11. FUEL INJECTION PUMP FOR INDIRECT INJECTION SYSTEM...................................................124
	11.1 EXPLODED VIEW (YPFR TYPE)......................................................................125
	11.2 DISASSEMBLY....................................................................................126
	11.3 INSPECTION.....................................................................................128
	11.4 REASSEMBLY.....................................................................................130
12. FUEL INJECTION PUMP FOR DIRECT INJECTION SYSTEM.....................................................132
	12.1 EXPLODED VIEW (YPES TYPE)......................................................................133
	12.2 SPECIAL SERVICE TOOLS FOR DISASSEMBLY AND REASSEMBLY...........................................135
	12.3 DISASSEMBLY....................................................................................136
	12.4 INSPECTION.....................................................................................141
	12.5 REASSEMBLY.....................................................................................143
13. GOVERNOR............................................................................................148
	13.1 EXPLODED VIEWS OF GOVERNOR FOR INDIRECT INJECTION SYSTEM.......................................149
	13.2 EXPLODED VIEWS OF GOVERNOR FOR DIRECT INJECTION SYSTEM.........................................151
	13.3 DISASSEMBLY....................................................................................153
	13.4 INSPECTION.....................................................................................159
	13.5 REASSEMBLY.....................................................................................161
14. TURBOCHARGER........................................................................................165
	14.1 SPECIFICATIONS.................................................................................166
	14.2 CONSTRUCTION...................................................................................167
	14.3 WASTE GATE VALVE ADJUSTING METHOD..............................................................169
	14.4 EXPLODED VIEW OF TURBOCHARGER (WITH WASTE GATE)................................................171
	14.5 TIGHTENING TORQUE..............................................................................172
	14.6 SERVICE STANDARDS..............................................................................172
15. SERVICE INFORMATION FOR CARB ULG REGULATION.........................................................173
	15.1 LIMITING THE HIGH IDLE AND LOW IDLE ADJUSTMENT SCREW...........................................174
	15.2 LIMITING THE FUEL VOLUME LIMITER SCREW.........................................................175
16. ATTACHED DRAWING....................................................................................176
	16.1 EXPLODED VIEWS OF ENGINE COMPONENTS............................................................177
	16.2 EXPLODED VIEWS OF ENGINE COMPONENTS............................................................179
20. EPA CERTIFIED ENGINE................................................................................181
	20.1 APPLICABLE MACHINE, SERIAL NUMBER (EPA CERTIFIED ENGINE).......................................182
	20.2 EPA CERTIFICATION PLATE ATTACHING LOCATION.....................................................183
	20.3 DIFFERENCES WITH THE CURRENT PRODUCTION MODEL..................................................184
	20.4 FUEL INJECTION TIMING ADJUSTMENT...............................................................185
	20.5 SECIFICATIONS..................................................................................196

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