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KOMATSU 82E-6-98E-6 SERIES ENGINE SHOP MANUAL SEN04211-04 – PDF DOWNLOAD
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Description
KOMATSU 82E-6-98E-6 SERIES ENGINE SHOP MANUAL SEN04211-04 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU 82E-6-98E-6 SERIES ENGINE SHOP MANUAL SEN04211-04 – PDF DOWNLOAD
Language : English
Pages : 382
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
KOMATSU 82E-6-98E-6 SERIES ENGINE SHOP MANUAL SEN04211-04 – PDF DOWNLOAD
Cover............................................................................................. 1 00 Index and foreword............................................................................. 3 Index......................................................................................... 3 Composition of shop manual................................................................ 4 Table of contents......................................................................... 5 Foreword and general information.............................................................. 9 Introduction.............................................................................. 10 Applicable machine model and serial number................................................ 11 Safety Statements......................................................................... 12 Safety Precautions........................................................................ 13 01 Specification.................................................................................. 35 Specification and technical data.............................................................. 35 Component identification...................................................................... 37 Function of major engine components........................................................... 39 Main electronic control components and features............................................... 40 Function of cooling system components......................................................... 42 Diesel fuel................................................................................... 43 Diesel fuel specifications................................................................ 43 Filling the fuel tank..................................................................... 44 Priming the fuel system................................................................... 46 Engine oil.................................................................................... 46 Engine oil specifications................................................................. 46 Checking engine oil....................................................................... 47 Adding engine oil......................................................................... 48 Engine oil capacity (typical)............................................................. 48 Engine coolant................................................................................ 49 Engine coolant specifications............................................................. 50 Filling radiator with engine coolant...................................................... 50 Engine coolant capacity (typical)......................................................... 51 Specifications................................................................................ 52 Description of Model Number............................................................... 52 Engine speed specifications............................................................... 52 Engine general specifications............................................................. 53 Principal engine specifications............................................................... 54 3D82AE (– EPA Tier2)...................................................................... 54 3D84E (– EPA Tier2)....................................................................... 55 S3D84E (– EPA Tier2)...................................................................... 56 3D88E (– EPA Tier2)....................................................................... 57 4D84E (– EPA Tier2)....................................................................... 58 S4D84E (– EPA Tier2)...................................................................... 59 4D88E (– EPA Tier2)....................................................................... 60 4D94LE (– EPA Tier2)...................................................................... 61 4D98E (– EPA Tier2)....................................................................... 62 S4D98E (– EPA Tier2)...................................................................... 63 3D82AE-B (complies with EPA Interim Tier4)................................................ 64 3D88E-U (complies with EPA Interim Tier4)................................................. 66 S4D84E-Z (complies with EPA Interim Tier4)................................................ 68 4D88E-U (complies with EPA Interim Tier4)................................................. 69 4D88E-B (complies with EPA Interim Tier4)................................................. 70 4D98E-E (complies with EPA Interim Tier4)................................................. 71 4D98E-Z (complies with EPA Interim Tier4)................................................. 72 S4D98E-Z (complies with EPA Tier3)........................................................ 73 Engine service standards...................................................................... 74 Tightening torques for standard bolts and nuts................................................ 75 Abbreviations and symbols..................................................................... 77 Abbreviations............................................................................. 77 Symbols................................................................................... 77 Unit conversions.............................................................................. 78 Unit prefixes............................................................................. 78 Units of length........................................................................... 78 Units of volume........................................................................... 78 Units of mass............................................................................. 78 Units of force............................................................................ 78 Units of torque........................................................................... 78 Units of pressure......................................................................... 78 Units of power............................................................................ 78 Units of temperature...................................................................... 78 30 Testing and adjusting..........................................................................231 Testing and adjusting, Part 1................................................................. 81 Before you begin servicing................................................................ 83 Introduction.............................................................................. 96 The importance of periodic maintenance................................................ 96 Performing periodic maintenance....................................................... 96 Komatsu replacement parts............................................................. 96 Required EPA / ARB maintenance - USA only............................................. 96 EPA / ARB installation requirements - USA only........................................ 96 Periodic maintenance schedule............................................................. 97 Periodic maintenance procedures...........................................................100 After initial 50 hours of operation...................................................100 Every 50 hours of operation...........................................................104 Every 250 hours of operation..........................................................107 Every 500 hours of operation..........................................................112 Every 1000 hours of operation.........................................................116 Every 1500 hours of operation.........................................................119 Every 2000 hours of operation.........................................................121 Testing and adjusting, Part 2.................................................................123 Before you begin servicing................................................................125 Introduction..............................................................................128 Cylinder head specifications..............................................................128 Adjustment specifications.............................................................128 Cylinder head.........................................................................128 Intake / exhaust valve and guide......................................................129 Push rod..............................................................................131 Rocker arm and shaft..................................................................131 Valve spring..........................................................................132 Camshaft and timing gear train specifications.............................................133 Camshaft..............................................................................133 Idler gear shaft and bushing..........................................................135 Timing gear backlash..................................................................135 Crankshaft and piston specifications......................................................136 Crankshaft............................................................................136 Thrust bearing........................................................................137 Piston................................................................................138 Piston ring...........................................................................140 Connecting rod........................................................................143 Tappet................................................................................144 Cylinder block specifications.............................................................145 Cylinder block........................................................................145 Special torque chart......................................................................146 Torque for bolts and nuts.............................................................146 Special service tools.....................................................................149 Measuring instruments.....................................................................153 2-valve cylinder head.....................................................................155 2-valve cylinder head components......................................................155 Components of a two-valve cylinder head...............................................156 Disassembly of 2-valve cylinder head..................................................157 Cleaning of cylinder head components..................................................161 Inspection of cylinder head components................................................161 Reassembly of cylinder head...........................................................165 4-valve cylinder head.....................................................................170 4-valve cylinder head components..........................................................170 Disassembly of 4-valve cylinder head..................................................171 Cleaning of cylinder head components..................................................176 Inspection of cylinder head components................................................177 Reassembly of cylinder head...........................................................182 Measuring and adjusting valve clearance...................................................187 2-valve cylinder heads................................................................188 4-valve cylinder heads................................................................189 Crankshaft and camshaft components........................................................192 Disassembly of engine.................................................................193 Disassembly of camshaft and timing components.........................................194 Disassembly of crankshaft and piston components.......................................199 Inspection of crankshaft and camshaft components......................................203 Honing and boring.....................................................................209 Reassembly of crankshaft and piston components........................................210 Reassembly of camshaft and timing components..........................................215 Final reassembly of engine............................................................219 EGR system................................................................................220 EGR system............................................................................220 EGR system............................................................................222 Inspecting/cleaning EGR related components............................................225 Testing and adjusting, Part 3.................................................................231 Before you begin servicing................................................................233 Introduction..............................................................................238 Fuel injection pump...................................................................238 Stop solenoid.........................................................................239 Cold start device.....................................................................239 Trochoid fuel pump....................................................................240 Electronically controlled governor....................................................240 Fuel system specifications................................................................241 Special torque chart..................................................................241 Test and adjustment specifications....................................................242 Special service tools.....................................................................243 Measuring instruments.....................................................................243 Fuel system diagram.......................................................................244 Fuel system components....................................................................245 2-valve cylinder head.................................................................245 4-valve cylinder head.................................................................247 Fuel injection pump.......................................................................249 Removal of fuel injection pump........................................................249 Installation of fuel injection pump...................................................254 Checking and adjusting fuel injection timing..............................................260 Determining the fuel injection timing specification...................................260 Checking fuel injection timing........................................................261 Adjusting fuel injection timing.......................................................264 Fuel injectors............................................................................265 Removal of fuel injectors.............................................................265 Testing of fuel injectors.............................................................268 Disassembly and inspection of fuel injectors..........................................269 Adjusting fuel injector pressure......................................................271 Reassembly of fuel injectors..........................................................271 Installation of the fuel injectors....................................................272 Testing and adjusting, Part 4.................................................................275 Before you begin servicing................................................................277 Introduction..............................................................................280 Cooling system diagram....................................................................280 Engine coolant pump components............................................................281 Engine coolant system check...............................................................282 Engine coolant pump.......................................................................282 Removal of engine coolant pump........................................................282 Disassembly of engine coolant pump....................................................284 Cleaning and inspection...............................................................284 Reassembly of engine coolant pump.....................................................285 Installation of engine coolant pump...................................................286 Testing and adjusting, Part 5.................................................................289 Before you begin servicing................................................................291 Introduction..............................................................................293 Oil pump service information..............................................................293 Lubrication system diagram................................................................296 Checking engine oil pressure..............................................................297 Trochoid oil pump.........................................................................297 3D82AE to 4D88E oil pump components...................................................297 Disassembly of oil pump...............................................................298 Cleaning and inspection...............................................................299 Reassembly of oil pump................................................................300 Trochoid oil pump.........................................................................301 3D82AE-B, 3D88E-B, 3D88E-U, 4D88E-B,4D88E-U, S3D84E-Z, S4D84E-Z Oil pumpcomponents....301 Disassembly of oil pump...............................................................302 Cleaning and inspection...............................................................302 Reassembly of oil pump................................................................304 Trochoid oil pump.........................................................................305 4D94LE/98E oil pump components........................................................305 Disassembly of oil pump...............................................................305 Cleaning and inspection...............................................................306 Reassembly of oil pump................................................................307 Testing and adjusting, Part 6.................................................................309 Before you begin servicing................................................................311 Introduction..............................................................................313 Specifications............................................................................313 Turbocharger service information......................................................313 Troubleshooting...........................................................................314 Excessive exhaust smoke...............................................................314 Generates white smoke.................................................................315 Sudden oil decrease...................................................................315 Decrease in output....................................................................315 Poor (slow) response (starting) of turbocharger.......................................315 Abnormal sound or vibration...........................................................315 Turbocharger components...................................................................316 Turbocharger component functions..........................................................318 Theory of operation...................................................................319 Compressor side sealing mechanism.....................................................319 Waste gate modulation.................................................................319 Waste gate modulation.....................................................................320 Periodic inspection.......................................................................321 Visual inspection.....................................................................321 Inspection of rotor rotation..........................................................321 Inspection of rotor play..............................................................321 Removal of turbocharger...............................................................321 Checking rotor play...................................................................322 Waste gate valve test.................................................................322 Installation of turbocharger..........................................................323 Testing and adjusting, Part 7.................................................................325 Before you begin servicing................................................................327 Introduction..............................................................................329 Starter motor information.................................................................329 3D82AE to 4D88E - Standard and optional...............................................329 4D94LE to S4D98E - Standard and optional..............................................330 Starter motor specifications..............................................................331 Starter motor troubleshooting.............................................................332 Starter motor components..................................................................333 Starter motor.............................................................................334 Removal of starter motor..............................................................334 Disassembly of starter motor..........................................................334 Cleaning and inspection...............................................................336 Reassembly of starter motor...........................................................341 Check pinion projection length........................................................342 No-load test..........................................................................343 Installation of starter motor.........................................................344 Testing and adjusting, Part 8.................................................................347 Before you begin servicing................................................................349 Introduction..............................................................................352 Dynamo and alternator information.........................................................352 3D82AE to S4D98E - Standard and optional dynamos......................................352 3D82AE to S4D98E - Standard and optional alternators..................................352 Alternator specifications.................................................................353 Dynamo specifications.....................................................................353 Alternator troubleshooting................................................................354 Alternator components.....................................................................355 Alternator wiring diagram.................................................................356 Alternator standard output................................................................357 Alternator................................................................................358 Removal of alternator.................................................................358 Disassembly of alternator.............................................................358 Reassembly of alternator..............................................................360 Installation of alternator............................................................362 Dynamo component location.................................................................363 Dynamo wiring diagram.....................................................................364 Operation of dynamo.......................................................................364 Dynamo standard output....................................................................365 Testing of dynamo.........................................................................366 Testing stator coil continuity........................................................366 Testing stator coil short-to-ground...................................................366 Testing dynamo regulated output.......................................................366 Dynamo....................................................................................366 Removal of dynamo.....................................................................366 Disassembly of dynamo.................................................................367 Reassembly of dynamo..................................................................367 Installation of dynamo................................................................368 40 Troubleshooting................................................................................371 Troubleshooting of mechanical system..........................................................371 Special service tools.....................................................................373 Troubleshooting by measuring compression pressure.........................................375 Compression pressure measurement method...............................................375 Quick reference table for troubleshooting.................................................378 Failure Diagnostic List...............................................................379
DESCRIPTION:
KOMATSU 82E-6-98E-6 SERIES ENGINE SHOP MANUAL SEN04211-04 – PDF DOWNLOAD
The contents of this shop manual are shown together with Form No. in a list.
Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly. The marks shown to the right of Form No. denote the following: Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.)
Note 2: This shop manual can be supplied for each Form No.
Note 3: To file this shop manual in the special binder for management, handle it as follows:
• Place a divider on the top of each section in the file after matching the Tub No. with No. indicated next to each Section Name shown in the table below:
• File overview and other materials in sections in the order shown below and utilize them accordingly.
Note 2: This shop manual can be supplied for each Form No.
Note 3: To file this shop manual in the special binder for management, handle it as follows:
• Place a divider on the top of each section in the file after matching the Tub No. with No. indicated next to each Section Name shown in the table below:
• File overview and other materials in sections in the order shown below and utilize them accordingly.
S.S 20/12/24
