Komatsu ENGINE 88E-7 SERIES Shop Manual SEN06599-00 – PDF DOWNLOAD

Description

Komatsu ENGINE 88E-7 SERIES Shop Manual SEN06599-00 – PDF DOWNLOAD

FILE DETAILS:

Komatsu ENGINE 88E-7 SERIES Shop Manual SEN06599-00 – PDF DOWNLOAD

Language : English
Pages :447
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu ENGINE 88E-7 SERIES Shop Manual SEN06599-00 – PDF DOWNLOAD

ITRODUCTION
How to read the shop manual
•Some of the attachments and options described in this shop manual may not be available in some areas. If they are required, consult your Komatsu distributor.
•The materials and specifications are subject to change without notice.
• Shop Manuals are available for “machine part” and “engine part”. For the engine unit, see the shop manual for the machine which has the same engine model.
• Actual machine may differ from the images which are contained in this manual. A typical model is shown in the illustrations of this shop manual.
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 information
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.

TABLE OF CONTENTS:

Komatsu ENGINE 88E-7 SERIES Shop Manual SEN06599-00 – PDF DOWNLOAD

Cover 1
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 Components100
Removal of pistons100
Removal of crankshaft101
Inspection of Crankshaft and Camshaft Components103
Replacement of crankshaft oil seals103
Measure crankshaft bearing oil clearance104
Inspection of cylinder block104
Inspection of pistons, piston rings and wrist pin104
Inspection of connecting rod106
Inspection of tappets106
Inspection of crankshaft107
Inspection of camshaft108
Inspection of camshaft bushing and bores108
Inspection of idler gear and shaft108
Honing and Boring109
Reassembly of Crankshaft and Piston Components110
Reassembly of pistons110
Installation of crankshaft113
Installation of pistons114
Reassembly of Camshaft and Timing Components115
Installation of gear case flange115
Installation of camshaft116
Installation of timing gears116
Installation of gear case cover117
Installation of oil pan117
Final Reassembly of Engine118
EGR system119
EGR System119
Disassembly of EGR System120
Inspecting/Cleaning EGR Related Components121
EGR valve121
EGR valve operation checks121
Cleaning the EGR valves122
EGR active control122
Exit the EGR active control123
Precautions for cleaning123
EGR pipe and other connecting elbows123
Installing EGR related components/parts123
Fuel System125
Before You Begin Servicing127
Cold start device128
Trochoid Fuel Pump128
Electronically Controlled Governor128
Fuel System Specifications129
Special Torque Chart129
Test and Adjustment Specifications130
Special Service Tools131
Measuring Instruments131
Fuel System Diagram132
Fuel System Components133
Fuel Injection Pump134
Removal of Fuel Injection Pump134
Installation of Fuel Injection Pump138
For electronically controlled engine138
Checking and Adjusting Fuel Injection Timing143
Determining the Fuel Injection Timing Specification143
Checking Fuel Injection Timing144
Adjusting Fuel Injection Timing146
Fuel Injectors148
Removal of Fuel Injectors148
Testing of Fuel Injectors149
Disassembly and Inspection of Fuel Injectors151
Adjusting Fuel Injector Pressure152
Reassembly of Fuel Injectors152
Installation of the Fuel Injectors153
Cooling System155
Before You Begin Servicing157
Introduction158
Cooling System Diagram158
Engine Coolant Pump Components159
Engine Coolant System Check160
Engine Coolant Pump160
Removal of Engine Coolant Pump160
Disassembly of Engine Coolant Pump161
Cleaning and Inspection162
Engine coolant temperature sensor162
Engine coolant temperature switch162
Thermostat162
Radiator cap163
Reassembly of Engine Coolant Pump163
Installation of Engine Coolant Pump163
Lubrication System165
Before You Begin Servicing167
Introduction168
Oil Pump Service Information168
Engine oil pressure168
Rotor shaft clearance168
Lubrication System Diagram169
Checking Engine Oil Pressure170
Trochoid Oil Pump170
Oil Pump Components170
Disassembly of Oil Pump171
Cleaning and Inspection172
Check outer rotor outside clearance172
Outer rotor to inner rotor tip clearance172
Check outer rotor side clearance172
Check rotor shaft clearance173
Reassembly of Oil Pump173
Starter Motor175
Before You Begin Servicing177
Introduction178
Starter Motor Information178
Standard and Optional178
Starter Motor Specifications179
Starter Motor Troubleshooting180
Starter Motor Components181
Starter Motor182
Removal of Starter Motor182
Disassembly of Starter Motor182
Inspection and Maintenance185
Reassembly191
No-load Test192
Installation of Starter Motor192
Alternator193
Before You Begin Servicing195
Introduction196
Alternator Information196
Standard and Optional Alternators196
Alternator Specifications196
Alternator Troubleshooting197
Alternator Components198
Alternator Wiring Diagram199
Alternator Standard Output200
Alternator201
Removal of Alternator201
Disassembly of Alternator201
Reassembly of Alternator203
Installation of Alternator205
ELECTRONIC CONTROL SYSTEM207
Before You Begin Servicing209
Introduction209
Electronic Control System210
Troubleshooting of Electronic Control System211
Fault Detection Capability211
SMARTASSIST-DIRECT (SA-D)213
Electric Wiring215
Electric Wiring Precautions217
Electrical Wire Resistance218
Battery Cable Resistance219
Electrical Wire Sizes – Voltage Drop220
Conversion of AWG to European Standards221
TROUBLESHOOTING223
FAILURE CODE (DTC) GENERAL DESCRIPTION225
Failure code (DTC) list228
Description Items231
Analog Input Related Failures232
Rack position sensor232
(1) #B1202: Failure with Rack Position Sensor (Low Voltage)232
(2) #B1203: Rack Position Sensor Error (High Voltage)234
Accelerator sensor236
(1) #B0122: Accelerator Sensor 1 (Low Voltage)236
(2) #B0123: Accelerator Sensor 1 (High Voltage)238
(3) #B0124: Accelerator Sensor 1 Intermittent Failure240
(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 Sensor264
(1) #B0668: ECU Temperature Sensor Error (Low Voltage)264
(2) #B0669: ECU Temperature Sensor Error (High Voltage)265
(3) #B1664: ECU Temperature Sensor Intermittent Failure266
(4) #B0634: ECU Temperature Rise Alarm267
Cooling water temperature sensor269
(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 Failure273
(4) #B0217: —275
SENSOR 5V277
(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 Failure279
Power supply Voltage280
(1) #B0562: Power Supply Voltage Error (Low Voltage)280
(2) #B0563: Power Supply Voltage Error (High Voltage)282
Pulse Sensor Related Failures284
Speed Sensor284
(1) #B0340: Speed Sensor Error284
Spare speed sensor (option)286
(1) #B1340: —286
Engine rotational speed288
(1) #B0219: Overspeed288
Contact Output Related Failures290
Rack actuator Relay290
(1) #B1222: Rack Actuator Relay Abnormality A290
DTC Detecting Conditions290
Movement at Error occurrence290
Estimation of Failure cause/Error condition290
Diagnosis Description291
(2) #B1223: Rack Actuator Relay Abnormality B292
DTC Detecting Conditions292
Movement at Error occurrence292
Estimation of Failure cause/Error condition292
Diagnosis Description293
(3) #B1224: Rack Actuator Relay Intermittent Failure294
DTC Detecting Conditions294
Movement at Error occurrence294
Estimation of Failure cause/Error condition294
Diagnosis Description295
Start Assist Relay296
(1) #B1232: Start Assist Relay Abnormality A296
DTC Detecting Conditions296
Movement at Error occurrence296
Estimation of Failure cause/Error condition296
Diagnosis Description297
(2) #B1233: Start Assist Relay Abnormality B298
DTC Detecting Conditions298
Movement at Error occurrence298
Estimation of Failure cause/Error condition298
Diagnosis Description299
(3) #B1234: Start Assist Relay Intermittent Failure300
DTC Detecting Conditions300
Movement at Error occurrence300
Estimation of Failure cause/Error condition300
Diagnosis Description301
CSD solenoid valve302
(1) #B1242: CSD solenoid valve Abnormality A302
DTC Detecting Conditions302
Movement at Error occurrence302
Estimation of Failure cause/Error condition302
Diagnosis Description303
(2) #B1243: CSD solenoid valve Abnormality B304
DTC Detecting Conditions304
Movement at Error occurrence304
Estimation of Failure cause/Error condition304
Diagnosis Description305
(3) #B1244: CSD solenoid valve Intermittent Failure306
DTC Detecting Conditions306
Movement at Error occurrence306
Estimation of Failure cause/Error condition306
Diagnosis Description307
EGR valve308
(1) #B1402: EGR Valve (Step Motor A-phase) Abnormality A308
DTC Detecting Conditions308
Movement at Error occurrence308
Estimation of Failure cause/Error condition308
Diagnosis Description309
(2) #B1403: EGR Valve (Step Motor A-phase) Abnormality B310
DTC Detecting Conditions310
Movement at Error occurrence310
Estimation of Failure cause/Error condition310
Diagnosis Description311
(3) #B1412: EGR Valve (Step Motor B-phase) Abnormality A312
DTC Detecting Conditions312
Movement at Error occurrence312
Estimation of Failure cause/Error condition312
Diagnosis Description313
(4) #B1413: EGR Valve (Step Motor B-phase) Abnormality B314
DTC Detecting Conditions314
Movement at Error occurrence314
Estimation of Failure cause/Error condition314
Diagnosis Description315
(5) #B1422: EGR Valve (Step Motor C-phase) Abnormality A316
DTC Detecting Conditions316
Movement at Error occurrence316
Estimation of Failure cause/Error condition316
Diagnosis Description317
(6) #B1423: EGR Valve (Step Motor C-phase) Abnormality B318
DTC Detecting Conditions318
Movement at Error occurrence318
Estimation of Failure cause/Error condition318
Diagnosis Description319
(7) #B1432: EGR Valve (Step Motor D-phase) Abnormality A320
DTC Detecting Conditions320
Movement at Error occurrence320
Estimation of Failure cause/Error condition320
Diagnosis Description321
(8) #B1433: EGR Valve (Step Motor D-phase) Abnormality B322
DTC Detecting Conditions322
Movement at Error occurrence322
Estimation of Failure cause/Error condition322
Diagnosis Description323
Contact Input Related Failures324
Oil Pressure Related Failures324
(1) #B1192: Oil Pressure Switch Open Circuit324
(2) #B1198: Oil Pressure Low Error Alarm326
Battery Charge Related Failures328
(1) #B1562: Charge Switch Open Circuit328
(2) #B1568: Charge Alarm330
Water Temperature Switch332
(1) #B1217: —332
Air cleaner switch334
(1) #B1101: —334
Oil-Water Separator Switch336
(1) #B1151: —336
Actuators etc338
Rack actuator338
(1) #B1212: Rack Actuator Abnormality (Low Current)338
(2) #B1213: Rack Actuator Abnormality (High Current)340
(3) #B1211: Rack Actuator Mechanical Failure342
Engine344
(1) #B1214: Engine Trouble344
E-ECU Internal and Communication Errors346
E-ECU Internal Errors346
(1) #B0605: FlashROM Error (Checksum A) 346
(2) #B0601: EEPROM Memory Deletion Error 347
(3) #B0686: Main Relay Error348
CAN Communication350
(1) #BG001: CAN Communication Error350
Immobilizer352
(1) #BG167: Immobilizer CAN Communication Error352
(2) #BH167: —354
(3) #BG426: Immobilizer System Error356
METHOD AND PROCEDURE OF FAILURE DIAGNOSIS357
Description Items359
E-ECU Pin Layout Diagram360
How to use the 2G eco-checker harness361
Analog Input Related Failures362
Rack position sensor362
Accelerator sensor366
Foot pedal370
Spare Analog (Spare accelerator sensor, Atmospheric pressure sensor)374
Pulse accelerator378
ECU Temperature Sensor380
Cooling water temperature sensor382
Sensor 5V386
Pulse Sensor Related Failures390
Speed Sensor390
Spare speed sensor393
Contact Output Related Failures396
Rack Actuator Relay396
Start Assist Relay400
CSD Solenoid Valve Coil404
EGR valve408
Contact Input Related Failures413
Actuator Related Failures419
Rack actuator419
ECU Internal and Communication Errors423
ECU Internal Errors423
Main relay425
CAN Communication429
Immobilizer431
Mechanical System Failure Diagnosis433
Special Service Tools435
Troubleshooting By Measuring Compression Pressure436
Compression Pressure Measurement Method436
Quick Reference Table For Troubleshooting440

IMAGES PREVIEW OF THE MANUAL:

S.M 24/12/24