KOMATSU 82E-98E SERIES SHOP MANUAL SEBM035103 – PDF DOWNLOAD

Description

KOMATSU 82E-98E SERIES SHOP MANUAL SEBM035103 – PDF DOWNLOAD

FILE DETAILS:

KOMATSU 82E-98E SERIES SHOP MANUAL SEBM035103 – PDF DOWNLOAD

Language : English
Pages : 197
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

KOMATSU 82E-98E SERIES SHOP MANUAL SEBM035103 – PDF DOWNLOAD

COVER.............................................................  1
CONTENTS.......................................................... 15
1. GENERAL ....................................................... 16
	1.1 SPECIFICATIONS............................................ 17
	1.2 ENGINE EXTERNAL VIEWS..................................... 29
	1.3 STRUCTURAL DESCRIPTION ................................... 30
2. INSPECTION ANG ADJUSTMENT...................................... 31
	2.1 PERIODIC MAINTENANCE SCHEDULE............................. 32
	2.2 PERIODIC INSPECTION AND MAINTENANCE PROCEDURE............. 33
		2.2.1 CHECK BEFORE DAILY OPERATION ....................... 33
		2.2.2 INSPECTION AFTER INITIAL 50 HOURS OPERATION ........ 35
		2.2.3 INSPECTION EVERY 50 HOURS .......................... 38
		2.2.4 INSPECTION EVERY 250 HOURS OR 3 MONTHS ............. 42
		2.2.5 INSPECTION EVERY 500 HOURS OR 6 MONTHS ............. 45
		2.2.6 INSPECTION EVERY 1000 HOURS OR ONE YEAR ............ 47
		2.2.7 INSPECTION EVERY 2000 HOURS OR 2 YEARS ............. 56
	2.3 ADJUSTING THE NO-LOAD MAXIMUM OR MINIMUM SPEED............ 59
	2.4 SENSOR INSPECTION ........................................ 59
		2.4.1 OIL PRESSURE SWITCH................................. 59
		2.4.2 THERMO SWITCH....................................... 59
	2.5 WATER LEAK CHECK IN COOLING WATER SYSTEM ................. 60
	2.6 RADIATOR CAP INSPECTION .................................. 60
	2.7 THERMOSTAT INSPECTION .................................... 61
	2.8 ADJUSTING OPERATION ...................................... 62
	2.9 LONG STORAGE.............................................. 62
3. TROUBLESHOOTING................................................ 63
	3.1 PREPARATION BEFORE TROUBLESHOOTING........................ 64
	3.2 QUICK REFERENCE TABLE FOR TROUBLESHOOTING ................ 65
	3.3 TROUBLESHOOTING BY MEASURING COMPRESSION PRESSURE......... 68
4. DISASSEMBLY, INSPECTION AND REASSEMBLY OF ENGINES.............. 70
	4.1 COMPLETE DISASSEMBLY AND REASSEMBLY....................... 71
		4.1.1 INTRODUCTION ....................................... 71
		4.1.2 SPECIAL SERVICE TOOLS............................... 72
		4.1.3 COMPLETE DISASSEMBLY................................ 77
		4.1.4 PRECAUTIONS BEFORE AND DURING REASSEMBLY............ 81
		4.1.5 ADJUSTING OPERATION ................................ 81
	4.2 CYLINDER HAED: DISASSEMBLY, INSPECTION AND REASSEMBLY..... 82
		4.2.1 COMPONENTS(2-VALVE CYLINDER HAED)................... 82
		4.2.2 DISASSEMBLY PROCEDURE............................... 82
		4.2.3 REASSEMBLY PROCEDURE................................ 83
		4.2.4 SERVICING POINTS.................................... 84
		4.2.5 PARTS INSPECTION AND MEASUREMENT.................... 88
		4.2.6 VALVE SEAT CORRECTION .............................. 92
		4.2.7 VALVE GUIDE REPLACEMENT............................. 93
		4.2.8 VALVE STEM SEAL REPLACEMENT......................... 94
	4.3 GEAR TRAIN AND CAMSHAFT................................... 95
		4.3.1 COMPONENTS.......................................... 95
		4.3.2 DISASSEMBLY PROCEDURE............................... 95
		4.3.3 REASSEMBLY PROCEDURE................................ 95
		4.3.4 SERVICING POINTS.................................... 96
		4.3.5 PARTS INSPECTION AND MEASUREMENT.................... 99
		4.3.6 OIL SEAL REPLACEMENT (GEAR CASE SIDE)...............101
		4.3.7 CAMSHAFT BUSHING REPLACEMENT........................101
	4.4 CYLINDER BLOCK............................................102
		4.4.1 COMPONENTS..........................................102
		4.4.2 DISASSEMBLY PROCEDURE...............................102
		4.4.3 REASSEMBLY PROCEDURE................................102
		4.4.4 SERVICING POINTS....................................103
		4.4.5 PARTS INSPECTION AND MEASUREMENT....................107
		4.4.6 CYLINDER BORE CORRECTION ...........................118
		4.4.7 PISTON PIN BUSHING REPLACEMENT......................119
		4.4.8 OIL SEAL REPLACEMENT (FLYWHEEL HOUSING SIDE)........119
5. LUBRICATION SYSTEM.............................................120
	5.1 LUBRICATION SYSTEM DIAGRAM................................121
	5.2 TROCHOID PUMP COMPONENTS..................................122
	5.3 DISASSEMBLY (REVERSE THE PROCEDURE BELOW FOR ASSEMBLY)....122
	5.4 SERVICING POINTS..........................................122
	5.5 PARTS INSPECTION AND MEASUREMENT..........................123
6. COOLING SYSTEM ................................................125
	6.1 COOLING WATER SYSTEM .....................................126
	6.2 COOLING WATER PUMP COMPONENTS.............................126
	6.3 DISASSEMBLY (REVERSE THE PROCEDURE BELOW FOR ASSEMBLY)....127
	6.4 SERVICING POINTS..........................................127
7. FUEL INJECTION PUMP/GOVERNOR...................................128
	7.1 INTRODUCTION .............................................129
	7.2 FUEL INJECTION PUMP.......................................129
		7.2.1 FUEL SYSTEM DIAGRAM.................................129
		7.2.2 EXTERNAL VIEW AND COMPONENTS........................130
		7.2.3 DISASSEMBLY PROCEDURE...............................130
		7.2.4 ASSEMBLY PROCEDURE..................................131
		7.2.5 SERVICING POINTS....................................131
8. TURBOCHARGER...................................................133
	8.1 STRUCTURE AND FUNCTIONS...................................134
		8.1.1 MAIN SPECIFICATIONS.................................134
		8.1.2 CONSTRUCTION........................................134
		8.1.3 STRUCTURAL AND FUNCTIONAL OUTLINE...................135
		8.1.4 COMPONENTS..........................................135
		8.1.5 COMPONENTS..........................................136
	8.2 SERVICE STANDARDS AND TIGHTENING TORQUE...................137
		8.2.1 SERVICE STANDARDS...................................137
		8.2.2 TIGHTENING TORQUE...................................138
	8.3 PERIODIC INSPECTION PROCEDURE.............................139
		8.3.1 PERIODIC INSPECTION INTERVALS.......................139
		8.3.2 INSPECTION PROCEDURE................................139
		8.3.3 WASTE GATE VALVE ADJUSTMENT PROCEDURE...............140
	8.4 DISASSEMBLY PROCEDURE.....................................142
		8.4.1 PREPARATION FOR DISASSEMBLY.........................142
		8.4.2 INSPECTION BEFORE DISASSEMBLY.......................143
		8.4.3 DISASSEMBLY.........................................143
	8.5 WASHING AND INSPECTION PROCEDURE..........................144
		8.5.1 WASHING.............................................144
		8.5.2 INSPECTION PROCEDURE................................145
	8.6 REASSEMBLY PROCEDURE......................................148
		8.6.1 PREPARATION FOR REASSEMBLY..........................148
		8.6.2 REASSEMBLY..........................................148
	8.7 HANDING AFTER DISASSEMBLY AND REASSEMBLY..................151
		8.7.1 INSTRUCTIONS FOR TURBOCHARGER INSTALLATION .........151
	8.8 TROUBLESHOOTING...........................................152
		8.8.1 EXCESSIVELY EXHAUST SMOKE...........................152
		8.8.2 WHITE SMOKE GENERATION .............................152
		8.8.3 SUDDEN OIL DECREASE.................................153
		8.8.4 DECREASE IN OUTPUT..................................153
		8.8.5 POOR (SLOW) RESPONSE (STARTING) OF TURBOCHARGER.....153
		8.8.6 ABNORMAL SOUND OR VIBRATION ........................153
9. STARTING MOTOR.................................................154
	9.1 FOR 4D94LE/(S)4D98E.......................................155
		9.1.1 SPECIFICATIONS......................................155
		9.1.2 COMPONENTS..........................................156
		9.1.3 TROUBLESHOOTING ....................................157
		9.1.4 NAMES OF PARTS AND DISASSEMBLY PROCEDURE............158
		9.1.5 INSPECTION AND MAINTENANCE..........................162
		9.1.6 SERVICE STANDARDS...................................167
		9.1.7 ASSEMBLY............................................168
		9.1.8 CHARACTERISTIC TEST.................................170
10. ALTERNATOR....................................................171
	10.1 THE 40A ALTERNATOR FOR 3D84E AND OTHER MODELS............172
		10.1.1 COMPONENTS.........................................172
		10.1.2 SPECIFICATIONS.....................................173
		10.1.3 WIRING DIAGRAM.....................................173
		10.1.4 STANDARD OUTPUT CHARACTERISTICS....................174
		10.1.5 INSPECTION ........................................174
		10.1.6 TROUBLESHOOTING....................................175
11. ELECTRIC WIRING...............................................176
	11.1 ELECTRIC WIRING DIAGRAM..................................177
	11.2 PRECAUTION ON ELECTRIC WIRING............................179
		11.2.1 ALTERNATOR.........................................179
		11.2.2 STARTING MOTOR.....................................180
		11.2.3 CURRENT LIMITER....................................181
		11.2.4 SECTION AREA AND RESISTANCE OF ELECTRIC WIRE.......182
12. SERVICE STANDARDS.............................................183
	12.1 ENGINE TUNING............................................184
	12.2 ENGINE BODY..............................................185
		12.2.1 CYLINDER HEAD .....................................185
		12.2.2 GEAR TRAIN AND CAMSHAFT............................188
		12.2.3 CYLINDER BLOCK.....................................189
	12.3 LUBRICATING OIL SYSTEM (TROCHOID PUMP)...................194
13. TIGHTENING TORQUE FOR BOLTS AND NUTS..........................195
	13.1 TIGHTENING TORQUES FOR MAIN BOLTS AND NUTS...............196
	13.2 TIGHTENING TORQUES FOR STANDARD BOLTS AND NUTS...........197

DESCRIPTION:

KOMATSU 82E-98E SERIES SHOP MANUAL SEBM035103 – PDF DOWNLOAD

• 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.

S.S 18/12/24