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KOMATSU 88E-7 SERIES ENGINE SHOP MANUAL SEN06599-02 – PDF DOWNLOAD
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Description
KOMATSU 88E-7 SERIES ENGINE SHOP MANUAL SEN06599-02 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU 88E-7 SERIES ENGINE SHOP MANUAL SEN06599-02 – PDF DOWNLOAD
Language : English
Pages : 452
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
KOMATSU 88E-7 SERIES ENGINE SHOP MANUAL SEN06599-02 – PDF DOWNLOAD
COVER............................................................................................. 3 Table of Contents................................................................................. 3 STRUCTURE AND FUNCTION,TESTING AND ADJUSTING,DISASSEMBLY AND ASSEMBLY,AND MAINTENANCE STANDARD.... 5 Introduction.................................................................................. 7 APPLICABLE MACHINE............................................................................ 9 Safety........................................................................................ 11 Safety Statements......................................................................... 13 Precautions for preparatory work...................................................... 13 Precautions during work............................................................... 13 Precautions for slinging work and making signals...................................... 14 Precautions for using mobile crane.................................................... 15 Precautions for using overhead traveling crane........................................ 16 Selecting wire ropes.................................................................. 17 Precautions for disposing of waste materials.......................................... 17 Drying wiring harness................................................................. 18 Handling controller................................................................... 19 Safety Precautions........................................................................ 20 General Service Information................................................................... 33 Component Identification.................................................................. 35 Function of Major Engine Components....................................................... 36 Function of Cooling System Components..................................................... 37 Main Electronic Control Components and Features........................................... 38 Diesel Fuel............................................................................... 40 Diesel Fuel Specifications............................................................ 40 Additional technical fuel requirements............................................ 40 Precautions and concerns regarding the use of diesel fuel......................... 40 Biodiesel fuels................................................................... 40 KIT parts list for B 20 (This series engine)...................................... 43 Filling The Fuel Tank................................................................. 44 Priming the Fuel System............................................................... 45 Engine Oil................................................................................ 46 Engine Oil Specifications............................................................. 46 Service categories................................................................ 46 Definitions....................................................................... 46 Additional technical engine oil requirements:..................................... 46 Engine Oil Viscosity.................................................................. 46 Checking Engine Oil................................................................... 47 Adding Engine Oil..................................................................... 47 Engine Oil Capacity (Typical)......................................................... 47 Engine Coolant............................................................................ 48 Filling Radiator with Engine Coolant.................................................. 49 Daily Check of the Cooling System..................................................... 49 Engine Coolant Capacity (Typical)..................................................... 49 Specifications............................................................................ 50 Description of Model Number........................................................... 50 Engine General Specifications......................................................... 50 Principal Engine Specifications........................................................... 51 Engine Service Standards.................................................................. 52 Tightening Torques for Standard Bolts and Nuts............................................ 53 Abbreviations and Symbols................................................................. 55 Abbreviations......................................................................... 55 Symbols............................................................................... 55 Unit Conversions.......................................................................... 56 Unit prefixes......................................................................... 56 Units of length....................................................................... 56 Units of volume....................................................................... 56 Units of mass......................................................................... 56 Units of force........................................................................ 56 Units of torque....................................................................... 56 Units of pressure..................................................................... 56 Units of power........................................................................ 56 Units of temperature.................................................................. 56 Periodic Maintenance.......................................................................... 57 Before You Begin Servicing................................................................ 59 Introduction.............................................................................. 60 The Importance of Periodic Maintenance................................................ 60 Performing Periodic Maintenance....................................................... 60 Komatsu Replacement Parts............................................................. 60 Required EPA/ARB Maintenance - USA Only............................................... 60 EPA/ARB Installation Requirements - USA Only.......................................... 60 Periodic Maintenance Schedule............................................................. 61 Periodic Maintenance Procedures........................................................... 62 Every 1000 Hours of Operation......................................................... 62 Check and adjust intake/exhaust valve clearance................................... 62 Every 1500 Hours of Operation......................................................... 62 Inspect and clean the fuel injection valve........................................ 62 Inspect crankcase breather system................................................. 62 Every 3000 Hours of Operation......................................................... 63 Inspect, clean and test EGR valve................................................. 63 Engine........................................................................................ 65 Before You Begin Servicing................................................................ 67 Introduction.............................................................................. 68 Cylinder Head Specifications.............................................................. 68 Adjustment Specifications............................................................. 68 Cylinder Head......................................................................... 68 Intake/Exhaust Valve and Guide........................................................ 68 Push Rod.............................................................................. 69 Rocker Arm and Shaft.................................................................. 69 Valve Spring.......................................................................... 69 Camshaft and Timing Gear Train Specifications............................................. 70 Camshaft.............................................................................. 70 Idler Gear Shaft and Bushing.......................................................... 70 Timing Gear Backlash.................................................................. 70 Crankshaft and Piston Specifications...................................................... 71 Crankshaft............................................................................ 71 Thrust Bearing........................................................................ 71 Piston................................................................................ 71 Piston Ring........................................................................... 72 Connecting Rod........................................................................ 72 Connecting rod small end.......................................................... 72 Connecting rod big end............................................................ 72 Tappet................................................................................ 73 Cylinder Block Specifications............................................................. 73 Cylinder Block........................................................................ 73 Special Torque Chart...................................................................... 74 Torque for Bolts and Nuts............................................................. 74 Special Service Tools..................................................................... 75 Measuring Instruments..................................................................... 77 Cylinder Head............................................................................. 79 Cylinder Head Components.............................................................. 79 Disassembly of Cylinder Head.......................................................... 80 Removal of cylinder head components............................................... 80 Removing the glow plugs........................................................... 81 Removal of rocker arm assembly.................................................... 82 Disassembly of rocker arm assembly................................................ 82 Removal of cylinder head.......................................................... 83 Removal of intake/exhaust valves.................................................. 83 Removal of valve guides........................................................... 84 Cleaning of Cylinder Head Components.................................................. 84 Inspection of Cylinder Head Components................................................ 84 Inspection of push rods........................................................... 84 Push rod bend................................................................. 84 Inspection of rocker arm assembly................................................. 85 Rocker arm shaft hole diameter................................................ 85 Rocker arm shaft outside diameter............................................. 85 Inspection of valve guides........................................................ 85 Inspection of cylinder head....................................................... 85 Cylinder head distortion...................................................... 85 Inspection of intake and exhaust valves........................................... 86 Valve stem diameter........................................................... 86 Valve stem bend............................................................... 86 Valve recession............................................................... 86 Grinding and lapping the valve seats.......................................... 87 Inspection of valve springs....................................................... 88 Fractures..................................................................... 88 Corrosion..................................................................... 88 Squareness.................................................................... 88 Free length................................................................... 88 Reassembly of Cylinder Head........................................................... 88 Reassembly of valve guides........................................................ 88 Reassembly of intake and exhaust valves........................................... 89 Reassembly of cylinder head....................................................... 90 Reassembly of rocker arm reassembly............................................... 90 Attaching the glow plug........................................................... 91 Attaching the fuel injection valve and the high pressure line..................... 91 Attaching the parts around the cylinder head...................................... 91 Measuring and Adjusting Valve Clearance................................................... 92 3-cylinder engines.................................................................... 92 Crankshaft and Camshaft................................................................... 94 Crankshaft and Camshaft Components.................................................... 94 Disassembly of Engine................................................................. 95 Disassembly of Camshaft and Timing Components......................................... 96 Removal of gear case cover........................................................ 96 Checking timing gear backlash..................................................... 96 Measuring idler gear-to-crankshaft gear backlash.................................. 96 Measuring idler gear-to-camshaft gear backlash.................................... 97 Removal of timing gears........................................................... 97 Removal of oil pan................................................................ 97 Removal of camshaft............................................................... 98 Removal of gear case flange....................................................... 99 Disassembly of Crankshaft and Piston Components.......................................100 Removal of pistons................................................................100 Removal of crankshaft.............................................................101 Inspection of Crankshaft and Camshaft Components......................................103 Replacement of crankshaft oil seals...............................................103 Measure crankshaft bearing oil clearance..........................................104 Inspection of cylinder block......................................................104 Inspection of pistons, piston rings and wrist pin.................................104 Inspection of connecting rod......................................................106 Inspection of tappets.............................................................106 Inspection of crankshaft..........................................................107 Inspection of camshaft............................................................108 Inspection of camshaft bushing and bores..........................................108 Inspection of idler gear and shaft................................................108 Honing and Boring.....................................................................109 Reassembly of Crankshaft and Piston Components........................................110 Reassembly of pistons.............................................................110 Installation of crankshaft........................................................113 Installation of pistons...........................................................114 Reassembly of Camshaft and Timing Components..........................................115 Installation of gear case flange..................................................115 Installation of camshaft..........................................................116 Installation of timing gears......................................................116 Installation of gear case cover...................................................117 Installation of oil pan...........................................................117 Final Reassembly of Engine............................................................118 EGR system................................................................................119 EGR System............................................................................119 Disassembly of EGR System.............................................................120 Inspecting/Cleaning EGR Related Components............................................121 EGR valve.........................................................................121 EGR valve operation checks........................................................121 Cleaning the EGR valves...........................................................122 EGR active control................................................................122 Exit the EGR active control.......................................................123 Precautions for cleaning..........................................................123 EGR pipe and other connecting elbows..............................................123 Installing EGR related components/parts...........................................123 Fuel System...................................................................................125 Before You Begin Servicing................................................................127 Cold start device.....................................................................128 Trochoid Fuel Pump....................................................................128 Electronically Controlled Governor....................................................128 Fuel System Specifications................................................................129 Special Torque Chart..................................................................129 Test and Adjustment Specifications....................................................130 Special Service Tools.....................................................................131 Measuring Instruments.....................................................................131 Fuel System Diagram.......................................................................132 Fuel System Components....................................................................133 Fuel Injection Pump.......................................................................134 Removal of Fuel Injection Pump........................................................134 Installation of Fuel Injection Pump...................................................138 For electronically controlled engine..............................................138 Checking and Adjusting Fuel Injection Timing..............................................143 Determining the Fuel Injection Timing Specification...................................143 Checking Fuel Injection Timing........................................................144 Adjusting Fuel Injection Timing.......................................................146 Fuel Injectors............................................................................148 Removal of Fuel Injectors.............................................................148 Testing of Fuel Injectors.............................................................149 Disassembly and Inspection of Fuel Injectors..........................................151 Adjusting Fuel Injector Pressure......................................................152 Reassembly of Fuel Injectors..........................................................152 Installation of the Fuel Injectors....................................................153 Cooling System................................................................................155 Before You Begin Servicing................................................................157 Introduction..............................................................................158 Cooling System Diagram....................................................................158 Engine Coolant Pump Components............................................................159 Engine Coolant System Check...............................................................160 Engine Coolant Pump.......................................................................160 Removal of Engine Coolant Pump........................................................160 Disassembly of Engine Coolant Pump....................................................161 Cleaning and Inspection...............................................................162 Engine coolant temperature sensor.................................................162 Engine coolant temperature switch.................................................162 Thermostat........................................................................162 Radiator cap......................................................................163 Reassembly of Engine Coolant Pump.....................................................163 Installation of Engine Coolant Pump...................................................163 Lubrication System............................................................................165 Before You Begin Servicing................................................................167 Introduction..............................................................................168 Oil Pump Service Information..............................................................168 Engine oil pressure...................................................................168 Rotor shaft clearance.................................................................168 Lubrication System Diagram................................................................169 Checking Engine Oil Pressure..............................................................170 Trochoid Oil Pump.........................................................................170 Oil Pump Components...................................................................170 Disassembly of Oil Pump...............................................................171 Cleaning and Inspection...............................................................172 Check outer rotor outside clearance...............................................172 Outer rotor to inner rotor tip clearance..........................................172 Check outer rotor side clearance..................................................172 Check rotor shaft clearance.......................................................173 Reassembly of Oil Pump................................................................173 Starter Motor.................................................................................175 Before You Begin Servicing................................................................177 Introduction..............................................................................178 Starter Motor Information.................................................................178 Standard and Optional.................................................................178 Starter Motor Specifications..............................................................179 Starter Motor Troubleshooting.............................................................180 Starter Motor Components..................................................................181 Starter Motor.............................................................................182 Removal of Starter Motor..............................................................182 Disassembly of Starter Motor..........................................................182 Inspection and Maintenance............................................................185 Reassembly............................................................................191 No-load Test..........................................................................192 Installation of Starter Motor.........................................................192 Alternator....................................................................................193 Before You Begin Servicing................................................................195 Introduction..............................................................................196 Alternator Information....................................................................196 Standard and Optional Alternators.....................................................196 Alternator Specifications.................................................................196 Alternator Troubleshooting................................................................197 Alternator Components.....................................................................198 Alternator Wiring Diagram.................................................................199 Alternator Standard Output................................................................200 Alternator................................................................................201 Removal of Alternator.................................................................201 Disassembly of Alternator.............................................................201 Reassembly of Alternator..............................................................203 Installation of Alternator............................................................205 ELECTRONIC CONTROL SYSTEM.....................................................................207 Before You Begin Servicing................................................................209 Introduction..............................................................................209 Electronic Control System.................................................................210 Troubleshooting of Electronic Control System..............................................211 Fault Detection Capability............................................................211 SMARTASSIST-DIRECT (SA-D).............................................................213 Electric Wiring...............................................................................215 Electric Wiring Precautions...............................................................217 Electrical Wire Resistance................................................................218 Battery Cable Resistance..................................................................219 Electrical Wire Sizes - Voltage Drop......................................................220 Conversion of AWG to European Standards...................................................221 TROUBLESHOOTING...................................................................................223 FAILURE CODE (DTC) GENERAL DESCRIPTION........................................................225 Failure code (DTC) list...................................................................228 Description Items.........................................................................231 Analog Input Related Failures.............................................................232 Rack position sensor..................................................................232 (1) #B1202: Failure with Rack Position Sensor (Low Voltage).......................232 (2) #B1203: Rack Position Sensor Error (High Voltage).............................234 Accelerator sensor....................................................................236 (1) #B0122: Accelerator Sensor 1 (Low Voltage)....................................236 (2) #B0123: Accelerator Sensor 1 (High Voltage)...................................238 (3) #B0124: Accelerator Sensor 1 Intermittent Failure.............................240 (4) #B1125: —.....................................................................242 (5) #B1126: —.....................................................................244 Spare accelerator sensor (option).....................................................246 (1) #B0222: —.....................................................................246 (2) #B0223: —.....................................................................248 (3) #B0224: —.....................................................................250 (4) #B1225: —.....................................................................252 (5) #B1226: —.....................................................................254 (6) #B1227: —.....................................................................256 Atmospheric pressure sensor (option)..................................................258 (1) #B2228: —.....................................................................258 (2) #B2229: —.....................................................................260 (3) #B2230: —.....................................................................262 ECU Temperature Sensor................................................................264 (1) #B0668: ECU Temperature Sensor Error (Low Voltage)............................264 (2) #B0669: ECU Temperature Sensor Error (High Voltage)...........................265 (3) #B1664: ECU Temperature Sensor Intermittent Failure...........................266 (4) #B0634: ECU Temperature Rise Alarm............................................267 Cooling water temperature sensor......................................................269 (1) #B0117: Cooling Water Temperature Sensor Error (Low Volt).....................269 (2) #B0118: Cooling Water Temperature Sensor Error (High Volt)....................271 (3) #B0119: Cooling Water Temp Sensor Intermittent Failure........................273 (4) #B0217: —.....................................................................275 SENSOR 5V.............................................................................277 (1) #B0642: 5V Sensor Power Voltage Error (Low Voltage)...........................277 (2) #B0643: 5V Sensor Power Voltage Error (High Voltage)..........................278 (3) #B1644: 5V Sensor Power Voltage Intermittent Failure..........................279 Power supply Voltage..................................................................280 (1) #B0562: Power Supply Voltage Error (Low Voltage)..............................280 (2) #B0563: Power Supply Voltage Error (High Voltage).............................282 Pulse Sensor Related Failures.............................................................284 Speed Sensor..........................................................................284 (1) #B0340: Speed Sensor Error....................................................284 Spare speed sensor (option)...........................................................286 (1) #B1340: —.....................................................................286 Engine rotational speed...............................................................288 (1) #B0219: Overspeed.............................................................288 Contact Output Related Failures...........................................................290 Rack actuator Relay...................................................................290 (1) #B1222: Rack Actuator Relay Abnormality A.....................................290 DTC Detecting Conditions..........................................................290 Movement at Error occurrence......................................................290 Estimation of Failure cause/Error condition.......................................290 Diagnosis Description.............................................................291 (2) #B1223: Rack Actuator Relay Abnormality B.....................................292 DTC Detecting Conditions..........................................................292 Movement at Error occurrence......................................................292 Estimation of Failure cause/Error condition.......................................292 Diagnosis Description.............................................................293 (3) #B1224: Rack Actuator Relay Intermittent Failure..............................294 DTC Detecting Conditions..........................................................294 Movement at Error occurrence......................................................294 Estimation of Failure cause/Error condition.......................................294 Diagnosis Description.............................................................295 Start Assist Relay....................................................................296 (1) #B1232: Start Assist Relay Abnormality A......................................296 DTC Detecting Conditions..........................................................296 Movement at Error occurrence......................................................296 Estimation of Failure cause/Error condition.......................................296 Diagnosis Description.............................................................297 (2) #B1233: Start Assist Relay Abnormality B......................................298 DTC Detecting Conditions..........................................................298 Movement at Error occurrence......................................................298 Estimation of Failure cause/Error condition.......................................298 Diagnosis Description.............................................................299 (3) #B1234: Start Assist Relay Intermittent Failure...............................300 DTC Detecting Conditions..........................................................300 Movement at Error occurrence......................................................300 Estimation of Failure cause/Error condition.......................................300 Diagnosis Description.............................................................301 CSD solenoid valve....................................................................302 (1) #B1242: CSD solenoid valve Abnormality A......................................302 DTC Detecting Conditions..........................................................302 Movement at Error occurrence......................................................302 Estimation of Failure cause/Error condition.......................................302 Diagnosis Description.............................................................303 (2) #B1243: CSD solenoid valve Abnormality B......................................304 DTC Detecting Conditions..........................................................304 Movement at Error occurrence......................................................304 Estimation of Failure cause/Error condition.......................................304 Diagnosis Description.............................................................305 (3) #B1244: CSD solenoid valve Intermittent Failure...............................306 DTC Detecting Conditions..........................................................306 Movement at Error occurrence......................................................306 Estimation of Failure cause/Error condition.......................................306 Diagnosis Description.............................................................307 EGR valve.............................................................................308 (1) #B1402: EGR Valve (Step Motor A-phase) Abnormality A..........................308 DTC Detecting Conditions..........................................................308 Movement at Error occurrence......................................................308 Estimation of Failure cause/Error condition.......................................308 Diagnosis Description.............................................................309 (2) #B1403: EGR Valve (Step Motor A-phase) Abnormality B..........................310 DTC Detecting Conditions..........................................................310 Movement at Error occurrence......................................................310 Estimation of Failure cause/Error condition.......................................310 Diagnosis Description.............................................................311 (3) #B1412: EGR Valve (Step Motor B-phase) Abnormality A..........................312 DTC Detecting Conditions..........................................................312 Movement at Error occurrence......................................................312 Estimation of Failure cause/Error condition.......................................312 Diagnosis Description.............................................................313 (4) #B1413: EGR Valve (Step Motor B-phase) Abnormality B..........................314 DTC Detecting Conditions..........................................................314 Movement at Error occurrence......................................................314 Estimation of Failure cause/Error condition.......................................314 Diagnosis Description.............................................................315 (5) #B1422: EGR Valve (Step Motor C-phase) Abnormality A..........................316 DTC Detecting Conditions..........................................................316 Movement at Error occurrence......................................................316 Estimation of Failure cause/Error condition.......................................316 Diagnosis Description.............................................................317 (6) #B1423: EGR Valve (Step Motor C-phase) Abnormality B..........................318 DTC Detecting Conditions..........................................................318 Movement at Error occurrence......................................................318 Estimation of Failure cause/Error condition.......................................318 Diagnosis Description.............................................................319 (7) #B1432: EGR Valve (Step Motor D-phase) Abnormality A..........................320 DTC Detecting Conditions..........................................................320 Movement at Error occurrence......................................................320 Estimation of Failure cause/Error condition.......................................320 Diagnosis Description.............................................................321 (8) #B1433: EGR Valve (Step Motor D-phase) Abnormality B..........................322 DTC Detecting Conditions..........................................................322 Movement at Error occurrence......................................................322 Estimation of Failure cause/Error condition.......................................322 Diagnosis Description.............................................................323 Contact Input Related Failures............................................................324 Oil Pressure Related Failures.........................................................324 (1) #B1192: Oil Pressure Switch Open Circuit......................................324 (2) #B1198: Oil Pressure Low Error Alarm..........................................326 Battery Charge Related Failures.......................................................328 (1) #B1562: Charge Switch Open Circuit............................................328 (2) #B1568: Charge Alarm..........................................................330 Water Temperature Switch..............................................................332 (1) #B1217: —.....................................................................332 Air cleaner switch....................................................................334 (1) #B1101: —.....................................................................334 Oil-Water Separator Switch............................................................336 (1) #B1151: —.....................................................................336 Actuators etc.............................................................................338 Rack actuator.........................................................................338 (1) #B1212: Rack Actuator Abnormality (Low Current)...............................338 (2) #B1213: Rack Actuator Abnormality (High Current)..............................340 (3) #B1211: Rack Actuator Mechanical Failure......................................342 Engine................................................................................344 (1) #B1214: Engine Trouble........................................................344 E-ECU Internal and Communication Errors...................................................346 E-ECU Internal Errors.................................................................346 (1) #B0605: FlashROM Error (Checksum A) ..........................................346 (2) #B0601: EEPROM Memory Deletion Error .........................................347 (3) #B0686: Main Relay Error......................................................348 CAN Communication.....................................................................350 (1) #BG001: CAN Communication Error...............................................350 Immobilizer...........................................................................352 (1) #BG167: Immobilizer CAN Communication Error...................................352 (2) #BH167: —.....................................................................354 (3) #BG426: Immobilizer System Error..............................................356 METHOD AND PROCEDURE OF FAILURE DIAGNOSIS.....................................................357 Description Items.........................................................................359 E-ECU Pin Layout Diagram..............................................................360 How to use the 2G eco-checker harness.................................................361 Analog Input Related Failures.............................................................362 Rack position sensor..................................................................362 Accelerator sensor....................................................................366 Foot pedal............................................................................370 Spare Analog (Spare accelerator sensor, Atmospheric pressure sensor)..................374 Pulse accelerator.....................................................................378 ECU Temperature Sensor................................................................380 Cooling water temperature sensor......................................................382 Sensor 5V.............................................................................386 Pulse Sensor Related Failures.............................................................390 Speed Sensor..........................................................................390 Spare speed sensor....................................................................393 Contact Output Related Failures...........................................................396 Rack Actuator Relay...................................................................396 Start Assist Relay....................................................................400 CSD Solenoid Valve Coil...............................................................404 EGR valve.............................................................................408 Contact Input Related Failures............................................................413 Actuator Related Failures.................................................................419 Rack actuator.........................................................................419 ECU Internal and Communication Errors.....................................................423 ECU Internal Errors...................................................................423 Main relay............................................................................425 CAN Communication.....................................................................429 Immobilizer...........................................................................431 Mechanical System Failure Diagnosis...........................................................433 Special Service Tools.....................................................................435 Troubleshooting By Measuring Compression Pressure.........................................436 Compression Pressure Measurement Method...............................................436 Quick Reference Table For Troubleshooting.................................................440
DESCRIPTION:
KOMATSU 88E-7 SERIES ENGINE SHOP MANUAL SEN06599-02 – PDF DOWNLOAD
Composition of the shop manual
This shop manual contains technical information necessary to perform services in workshops. It is divided into “Structure and Function, Testing and Adjusting, Disassembly and Assembly, and Maintenance Standard” and “Troubleshooting” section for the ease of use.
Basic informaton
This Shop Manual describes the service procedures for 3D88E-7 series direct injection engines. Please use this manual for accurate, quick and safe servicing of the engine. Since the directions in this manual are for a typical engine, some specifications and components may be different from your engine.
Komatsu products are continuously undergoing improvement. This Shop Manual might not address possible field modifications to the equipment. Contact an authorized Komatsu distributor for answers to any questions relating to field modifications.
S.S 25/12/24
