Komatsu 68E-88E Series Diesel Engine Repair Manual SEBM011501 PDF

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KOMATSU 68E-88E SERIES DIESEL ENGINE SHOP MANUAL SEBM011501 – PDF DOWNLOAD

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KOMATSU 68E-88E SERIES DIESEL ENGINE SHOP MANUAL SEBM011501 – PDF DOWNLOAD

Language : English
Pages : 204
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

KOMATSU 68E-88E SERIES DIESEL ENGINE SHOP MANUAL SEBM011501 – PDF DOWNLOAD

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

S.S 19/12/24