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Komatsu 82E-6 98E-6 Series Diesel Engine Shop Manual – PDF DOWNLOAD
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Description
Komatsu 82E-6 98E-6 Series Diesel Engine Shop Manual
FILE DETAILS:
Komatsu 82E-6 98E-6 Series Diesel Engine Shop Manual
Brands: Komatsu
Equipment Type: Diesel Engine
Manuals Type: Shop Manual
Machine Model: 82E-6, 98E-6 Series Engine
Serial Number: –
Book Code: SEN04211-03
Language: English
Pages: 385
DESCRIPTION:
Komatsu 82E-6 98E-6 Series Diesel Engine Shop Manual
INTRODUCTION:
- This manual describes the maintenance procedure for 82E-6 – 98E-6 Series engines (direct injection type). The contents of this manual shall be used as materials for correct, quick and safe maintenance of the above engines.
- Since this manual explains the maintenance procedure for the standard engine, the specifications and component parts shown below are partly different from those of the engine mounted on each work equipment (generator, pump, compressor, etc.) This shop manual consists of volumes.
- Some volumes titled “Testing and adjusting” [Testing and adjusting, Part 1 – Part 8] contain descriptions related to disassembly and assembly. For the contents of description, see the general contents or the contents of each volume.
TABLE OF CONTENTS:
Komatsu 82E-6 98E-6 Series Diesel Engine Shop Manual
COVER............................................................................................... 1 00 Index and foreword............................................................................... 2 Index........................................................................................... 2 Composition of shop manual.................................................................. 3 Table of contents........................................................................... 4 Foreword and general information................................................................ 8 Introduction................................................................................ 9 Applicable machine model and serial number.................................................. 10 Safety Statements........................................................................... 11 Safety Precautions.......................................................................... 12 01 Specification.................................................................................... 34 Specification and technical data................................................................ 34 Component identification.................................................................... 36 Function of major engine components......................................................... 38 Main electronic control components and features............................................. 39 Function of cooling system components....................................................... 41 Diesel fuel................................................................................. 42 Diesel fuel specifications.............................................................. 42 Filling the fuel tank................................................................... 43 Priming the fuel system................................................................. 45 Engine oil.................................................................................. 45 Engine oil specifications............................................................... 45 Engine oil viscosity.................................................................... 46 Checking engine oil..................................................................... 46 Adding engine oil....................................................................... 47 Engine oil capacity (typical)........................................................... 47 Engine coolant.............................................................................. 48 Engine coolant specifications........................................................... 49 Filling radiator with engine coolant.................................................... 49 Engine coolant capacity (typical)....................................................... 50 Specifications.............................................................................. 51 Description of Model Number............................................................. 51 Engine speed specifications............................................................. 51 Engine general specifications........................................................... 52 Principal engine specifications............................................................. 53 3D82AE (– EPA Tier2).................................................................... 53 3D84E (– EPA Tier2)..................................................................... 54 S3D84E (– EPA Tier2).................................................................... 55 3D88E (– EPA Tier2)..................................................................... 56 4D84E (– EPA Tier2)..................................................................... 57 S4D84E (– EPA Tier2).................................................................... 58 4D88E (– EPA Tier2)..................................................................... 59 4D94LE (– EPA Tier2).................................................................... 60 4D98E (– EPA Tier2)..................................................................... 61 S4D98E (– EPA Tier2).................................................................... 62 3D82AE-B (complies with EPA Interim Tier4).............................................. 63 S3D84E-B (complies with EPA Interim Tier4).............................................. 64 3D88E-U (complies with EPA Interim Tier4)............................................... 65 3D88E-B (complies with EPA Interim Tier4)............................................... 66 S4D84E-Z (complies with EPA Interim Tier4).............................................. 67 4D88E-U (complies with EPA Interim Tier4)............................................... 68 4D88E-B (complies with EPA Interim Tier4)............................................... 69 4D98E-E (complies with EPA Interim Tier4)............................................... 70 4D98E-Z (complies with EPA Interim Tier4)............................................... 71 S4D98E-Z (complies with EPA Tier3)...................................................... 72 Engine service standards.................................................................... 73 Tightening torques for standard bolts and nuts.............................................. 74 Abbreviations and symbols................................................................... 76 Abbreviations........................................................................... 76 Symbols................................................................................. 76 Unit conversions............................................................................ 77 Unit prefixes........................................................................... 77 Units of length......................................................................... 77 Units of volume......................................................................... 77 Units of mass........................................................................... 77 Units of force.......................................................................... 77 Units of torque......................................................................... 77 Units of pressure....................................................................... 77 Units of power.......................................................................... 77 Units of temperature.................................................................... 77 30 Testing and adjusting............................................................................ 80 Testing and adjusting, Part 1................................................................... 80 Before you begin servicing.................................................................. 82 Introduction................................................................................ 95 The importance of periodic maintenance.................................................. 95 Performing periodic maintenance......................................................... 95 Komatsu replacement parts............................................................... 95 Required EPA / ARB maintenance - USA only............................................... 95 EPA / ARB installation requirements - USA only.......................................... 95 Periodic maintenance schedule............................................................... 96 Periodic maintenance procedures............................................................. 99 After initial 50 hours of operation..................................................... 99 Every 50 hours of operation.............................................................103 Every 250 hours of operation............................................................106 Every 500 hours of operation............................................................111 Every 1000 hours of operation...........................................................115 Every 1500 hours of operation...........................................................118 Every 2000 hours of operation...........................................................120 Testing and adjusting, Part 2...................................................................122 Before you begin servicing..................................................................124 Introduction................................................................................127 Cylinder head specifications................................................................127 Adjustment specifications...............................................................127 Cylinder head...........................................................................127 Intake / exhaust valve and guide........................................................128 Push rod................................................................................130 Rocker arm and shaft....................................................................130 Valve spring............................................................................131 Camshaft and timing gear train specifications...............................................132 Camshaft................................................................................132 Idler gear shaft and bushing............................................................134 Timing gear backlash....................................................................134 Crankshaft and piston specifications........................................................135 Crankshaft..............................................................................135 Thrust bearing..........................................................................136 Piston..................................................................................137 Piston ring.............................................................................139 Connecting rod..........................................................................142 Tappet..................................................................................143 Cylinder block specifications...............................................................144 Cylinder block..........................................................................144 Special torque chart........................................................................145 Torque for bolts and nuts...............................................................145 Special service tools.......................................................................148 Measuring instruments.......................................................................152 2-valve cylinder head.......................................................................154 2-valve cylinder head components........................................................154 Components of a two-valve cylinder head.................................................155 Disassembly of 2-valve cylinder head....................................................156 Cleaning of cylinder head components....................................................160 Inspection of cylinder head components..................................................160 Reassembly of cylinder head.............................................................164 4-valve cylinder head.......................................................................169 4-valve cylinder head components........................................................169 Disassembly of 4-valve cylinder head....................................................170 Cleaning of cylinder head components....................................................175 Inspection of cylinder head components..................................................176 Reassembly of cylinder head.............................................................181 Measuring and adjusting valve clearance.....................................................186 2-valve cylinder heads..................................................................187 4-valve cylinder heads..................................................................188 Crankshaft and camshaft components..........................................................191 Disassembly of engine...................................................................192 Disassembly of camshaft and timing components...........................................193 Disassembly of crankshaft and piston components.........................................198 Inspection of crankshaft and camshaft components........................................202 Honing and boring.......................................................................208 Reassembly of crankshaft and piston components..........................................209 Reassembly of camshaft and timing components............................................214 Final reassembly of engine..............................................................218 EGR system..................................................................................219 EGR system..............................................................................219 EGR system..............................................................................221 Inspecting/cleaning EGR related components..............................................224 Testing and adjusting, Part 3...................................................................230 Before you begin servicing..................................................................232 Introduction................................................................................237 Fuel injection pump.....................................................................237 Stop solenoid...........................................................................238 Cold start device.......................................................................238 Trochoid fuel pump......................................................................239 Electronically controlled governor......................................................239 Fuel system specifications..................................................................240 Special torque chart....................................................................240 Test and adjustment specifications......................................................241 Special service tools.......................................................................242 Measuring instruments.......................................................................242 Fuel system diagram.........................................................................243 Fuel system components......................................................................244 2-valve cylinder head...................................................................244 4-valve cylinder head...................................................................246 Fuel injection pump.........................................................................248 Removal of fuel injection pump..........................................................248 Installation of fuel injection pump.....................................................253 Checking and adjusting fuel injection timing................................................259 Determining the fuel injection timing specification.....................................259 Checking fuel injection timing..........................................................260 Adjusting fuel injection timing.........................................................263 Fuel injectors..............................................................................264 Removal of fuel injectors...............................................................264 Testing of fuel injectors...............................................................267 Disassembly and inspection of fuel injectors............................................268 Adjusting fuel injector pressure........................................................270 Reassembly of fuel injectors............................................................270 Installation of the fuel injectors......................................................271 Testing and adjusting, Part 4...................................................................274 Before you begin servicing..................................................................276 Introduction................................................................................279 Cooling system diagram......................................................................279 Engine coolant pump components..............................................................280 Engine coolant system check.................................................................281 Engine coolant pump.........................................................................281 Removal of engine coolant pump..........................................................281 Disassembly of engine coolant pump......................................................283 Cleaning and inspection.................................................................283 Reassembly of engine coolant pump.......................................................284 Installation of engine coolant pump.....................................................285 Testing and adjusting, Part 5...................................................................288 Before you begin servicing..................................................................290 Introduction................................................................................292 Oil pump service information................................................................292 Lubrication system diagram..................................................................295 Checking engine oil pressure................................................................296 Trochoid oil pump...........................................................................296 3D82AE to 4D88E oil pump components.....................................................296 Disassembly of oil pump.................................................................297 Cleaning and inspection.................................................................298 Reassembly of oil pump..................................................................299 Trochoid oil pump...........................................................................300 3D82AE-B, 3D88E-B, 3D88E-U, 4D88E-B, 4D88E-U, S3D84E-Z, S4D84E-Z Oil pump components....300 Disassembly of oil pump.................................................................301 Cleaning and inspection.................................................................301 Reassembly of oil pump..................................................................303 Trochoid oil pump...........................................................................304 4D94LE/98E oil pump components..........................................................304 Disassembly of oil pump.................................................................304 Cleaning and inspection.................................................................305 Reassembly of oil pump..................................................................306 Testing and adjusting, Part 6...................................................................308 Before you begin servicing..................................................................310 Introduction................................................................................312 Specifications..............................................................................312 Turbocharger service information........................................................312 Troubleshooting.............................................................................313 Excessive exhaust smoke.................................................................313 Generates white smoke...................................................................314 Sudden oil decrease.....................................................................314 Decrease in output......................................................................314 Poor (slow) response (starting) of turbocharger.........................................314 Abnormal sound or vibration.............................................................314 Turbocharger components.....................................................................315 Turbocharger component functions............................................................317 Theory of operation.....................................................................318 Compressor side sealing mechanism.......................................................318 Waste gate modulation...................................................................318 Washing procedure...........................................................................319 Periodic inspection.........................................................................320 Visual inspection.......................................................................320 Inspection of rotor rotation............................................................320 Inspection of rotor play................................................................320 Removal of turbocharger.................................................................320 Checking rotor play.....................................................................321 Waste gate valve test...................................................................321 Waste gate actuator leak test...........................................................322 Installation of turbocharger............................................................322 Testing and adjusting, Part 7...................................................................324 Before you begin servicing..................................................................326 Introduction................................................................................328 Starter motor information...................................................................328 3D82AE to 4D88E - Standard and optional.................................................328 4D94LE to S4D98E - Standard and optional................................................329 Starter motor specifications................................................................330 Starter motor troubleshooting...............................................................331 Starter motor components....................................................................332 Starter motor...............................................................................333 Removal of starter motor................................................................333 Disassembly of starter motor............................................................333 Cleaning and inspection.................................................................335 Reassembly of starter motor.............................................................340 Check pinion projection length..........................................................341 No-load test............................................................................342 Installation of starter motor...........................................................343 Testing and adjusting, Part 8...................................................................346 Before you begin servicing..................................................................348 Introduction................................................................................351 Dynamo and alternator information...........................................................351 3D82AE to S4D98E - Standard and optional dynamos........................................351 3D82AE to S4D98E - Standard and optional alternators....................................351 Alternator specifications...................................................................352 Dynamo specifications.......................................................................352 Alternator troubleshooting..................................................................353 Alternator components.......................................................................354 Alternator wiring diagram...................................................................355 Alternator standard output..................................................................356 Alternator..................................................................................357 Removal of alternator...................................................................357 Disassembly of alternator...............................................................357 Reassembly of alternator................................................................359 Installation of alternator..............................................................361 Dynamo component location...................................................................362 Dynamo wiring diagram.......................................................................363 Operation of dynamo.........................................................................363 Dynamo standard output......................................................................364 Testing of dynamo...........................................................................365 Testing stator coil continuity..........................................................365 Testing stator coil short-to-ground.....................................................365 Testing dynamo regulated output.........................................................365 Dynamo......................................................................................365 Removal of dynamo.......................................................................365 Disassembly of dynamo...................................................................366 Reassembly of dynamo....................................................................366 Installation of dynamo..................................................................367 40 Troubleshooting..................................................................................370 Troubleshooting of mechanical system............................................................370 Special service tools.......................................................................372 Troubleshooting by measuring compression pressure...........................................374 Compression pressure measurement method.................................................374 Quick reference table for troubleshooting...................................................377 Failure Diagnostic List.................................................................378
KOMATSU 82E-6 98E-6 SERIES DIESEL ENGINE SHOP MANUAL – PDF DOWNLOAD:
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- This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
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