Komatsu 82E-98E Series Diesel Engine Shop Manual SEBM035102 – PDF DOWNLOAD

Description

Komatsu 82E-98E Series Diesel Engine Shop Manual SEBM035102 – PDF DOWNLOAD

FILE DETAILS:

Komatsu 82E-98E Series Diesel Engine Shop Manual SEBM035102 – PDF DOWNLOAD

Language : English
Pages :206
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu 82E-98E Series Diesel Engine Shop Manual SEBM035102 – PDF DOWNLOAD

PREFACE
This manual describes the service procedures for the 82E – 98E series engines of indirect injection system. Please use this manual for accurate, quick and safe servicing of the said engine. Since the explanation in this manual assumes the standard type engine, the specifications and components may partially be different from the engine installed on individual machine. Please also refer to the shop manual for each machine for details.

HOW TO READ THIS MANUAL

1. Range of Operation Explanation
This manual explains the troubleshooting, installation/removal, replacement, disassemble/reassembly, inspection, adjustment and adjusting operation procedures for the 82E-5 to 98E-5 series engines with direct injection system. Refer to the shop manual for each of the fuel injection pump, governor, starting motor and alternator except
for their installation.

2. How to Read the Explanations
• An exploded view, sectional views, a system diagram, etc. are shown at the beginning of each section
as required for easy understanding of the mounted states of the components.
• For the removal/installation of each part, the procedure is shown with the procedural step No. in the illustration.
• Precautions and key points for disassembly and reassembly of parts are described as points. In the
explanation for each point, detailed operation method, information, standard and precautions are described.

TABLE OF CONTENTS:

Komatsu 82E-98E Series Diesel Engine Shop Manual SEBM035102 – PDF DOWNLOAD

MAIN MENU 0
COVER 1
PREFACE 2
SAFETY LABELS 5
SAFETY PRECAUTIONS 6
PRECAUTIONS FOR SERVICE WORK 10
HOW TO READ THIS MANUAL 11
APPLICATION CATEGORY 13
APPLICABLE MACHINE, SERIAL NUMBER 14
CONTENTS 15
1 GENERAL 16
11 Specifications 17
12 Engine External Views 29
13 Structural Description 30
2 INSPECTION AND ADJUSTMENT 31
21 Periodic Maintenance Schedule 32
22 Periodic Inspection and Maintenance Procedure 33
221 Check before daily operation 33
222 Inspection after initial 50 hours operation 35
223 Inspection every 50 hours 38
224 Inspection every 250 hours or 3 months 42
225 Inspection every 500 hours or 6 months 45
226 Inspection every 1,000 hours or one year 47
227 Inspection every 2000 hours or 2 years 56
23 Adjusting the No-load Maximum or Minimum Speed 59
24 Sensor Inspection 59
241 Oil pressure switch 59
242 Thermo switch 59
25 Water Leak Check in Cooling Water System 60
26 Radiator Cap Inspection 60
27 Thermostat Inspection 61
28 Adjusting Operation 62
29 Long Storage 62
3 TROUBLESHOOTING 63
31 Preparation Before Troubleshooting 64
32 Quick Reference Table for Troubleshooting 65
33 Troubleshooting by Measuring Compression Pressure 68
4 DISASSEMBLY, INSPECTION AND REASSEMBLY OF ENGINES 71
41 Complete Disassembly and Reassembly 72
411 Introduction 72
412 Special service tools 73
413 Complete disassembly 78
414 Precautions before and during reassembly 82
415 Adjusting operation 82
42 Cylinder Head: Disassembly, Inspection and Reassembly 83
421 Components (2-valve cylinder head) 83
422 Disassembly procedure 83
423 Reassembly procedure 84
424 Servicing points 85
425 Parts inspection and measurement 89
426 Valve seat correction 93
427 Valve guide replacement 94
428 Valve stem seal replacement 95
43 Gear Train and Camshaft 96
431 Components 96
432 Disassembly procedure 96
433 Reassembly procedure 96
434 Servicing points 97
435 Parts inspection and measurement100
436 Oil seal replacement (Gear case side)102
437 Camshaft bushing replacement102
44 Cylinder Block103
441 Components103
442 Disassembly procedure:103
443 Reassembly procedure:103
444 Servicing points104
445 Parts inspection and measurement108
446 Cylinder bore correction119
447 Piston pin bushing replacement120
448 Oil seal replacement (Flywheel housing side)120
5 LUBRICATION SYSTEM121
51 Lubrication System Diagram122
52 Trochoid Pump Components123
53 Disassembly (Reverse the procedure below for assembly)123
54 Servicing Points123
55 Parts Inspection and Measurement124
6 COOLING SYSTEM127
61 Cooling Water System128
62 Cooling Water Pump Components128
63 Disassembly (Reverse the procedure below for assembly)129
64 Servicing Points129
7 FUEL INJECTION PUMP/GOVERNOR131
71 Introduction132
72 Fuel Injection Pump132
721 Fuel system diagram132
722 External view and components133
723 Disassembly procedure133
724 Assembly procedure134
725 Servicing points134
8 TURBOCHARGER137
81 Structure and Functions138
811 Main specifications138
812 Construction138
813 Structural and functional outline139
814 Components139
815 Components140
82 Service Standards and Tightening Torque141
821 Service standards141
822 Tightening torque142
83 Periodic Inspection Procedure143
831 Periodic inspection intervals143
832 Inspection procedure143
833 Waste gate valve adjustment procedure144
84 Disassembly Procedure146
841 Preparation for disassembly146
842 Inspection before disassembly147
843 Disassembly147
85 Washing and Inspection Procedure148
851 Washing148
852 Inspection procedure149
86 Reassembly Procedure152
861 Preparation for reassembly152
862 Reassembly152
87 Handling after Disassembly and Reassembly155
871 Instructions for turbocharger installation155
88 Troubleshooting156
881 Excessively exhaust smoke156
882 White smoke generation156
883 Sudden oil decrease157
884 Decrease in output157
885 Poor (slow) response (starting) of turbocharger157
886 Abnormal sound or vibration157
9 STARTING MOTOR159
91 For 4D94LE/(S)4D98E160
911 Specifications160
912 Components161
913 Troubleshooting162
914 Names of parts and disassembly procedure163
915 Inspection and maintenance167
916 Service standards172
917 Assembly173
918 Characteristic test175
10 ALTERNATOR177
101 The 40A Alternator for 3D84E and Other Models178
1011 Components178
1012 Specifications179
1013 Wiring diagram179
1014 Standard output characteristics180
1015 Inspection180
1016 Troubleshooting181
11 ELECTRIC WIRING183
111 Electric Wiring Diagram184
112 Precaution on Electric Wiring186
1121 Alternator186
1122 Starting motor187
1123 Current limiter188
1124 Section area and resistance of electric wire189
12 SERVICE STANDARDS191
121 Engine Tuning192
122 Engine Body193
1221 Cylinder head193
1222 Gear train and camshaft196
1223 Cylinder block197
123 Lubricating Oil System (Trochoid Pump)202
13 TIGHTENING TORQUE FOR BOLTS AND NUTS203
131 Tightening Torques for Main Bolts and Nuts204
132 Tightening Torques for Standard Bolts and Nuts205

IMAGES PREVIEW OF THE MANUAL:

S.M 16/12/24