Komatsu 82E-5, 98E-5 Series Diesel Engine Shop Manual SEBM035101

Description

• Model List:
  • 82E-5 Series Diesel Engine
  • 98E-5 Series Diesel Engine

• 1. MAIN MENU
• 2. COVER
• 3. PREFACE
• 4. SAFETY LABELS
• 5. SAFETY PRECAUTIONS
• 6. PRECAUTIONS FOR SERVICE WORK
• 7. HOW TO READ THIS MANUAL
• 8. APPLICATION CATEGORY
• 9. APPLICABLE MACHINE, SERIAL NUMBER
• 10. CONTENTS
• 11. GENERAL
• 11.1. Specifications
• 11.2. Engine External Views
• 11.3. Structural Description
• 12. INSPECTION AND ADJUSTMENT
• 12.1. Periodic Maintenance Schedule
• 12.2. Periodic Inspection and Maintenance Procedure
• 12.3. Check before daily operation
• 12.4. Inspection after initial 50 hours operation
• 12.5. Inspection every 50 hours
• 12.6. Inspection every 250 hours or 3 months
• 12.7. Inspection every 500 hours or 6 months
• 12.8. Inspection every 1,000 hours or one year
• 12.9. Inspection every 2000 hours or 2 years
• 12.10. Adjusting the Noload Maximum or Minimum Speed
• 12.11. Sensor Inspection
• 12.12. Oil pressure switch
• 12.13. Thermo switch
• 12.14. Water Leak Check in Cooling Water System
• 12.15. Radiator Cap Inspection
• 12.16. Thermostat Inspection
• 12.17. Adjusting Operation
• 12.18. Long Storage
• 13. TROUBLESHOOTING
• 13.1. Preparation Before Troubleshooting
• 13.2. Quick Reference Table for Troubleshooting
• 13.3. Troubleshooting by Measuring Compression Pressure
• 14. DISASSEMBLY, INSPECTION AND REASSEMBLY OF ENGINES
• 14.1. Complete Disassembly and Reassembly
• 14.2. Introduction
• 14.3. Special service tools
• 14.4. Complete disassembly
• 14.5. Precautions before and during reassembly
• 14.6. Adjusting operation
• 14.7. Cylinder Head Disassembly, Inspection and Reassembly
• 14.8. Components (2valve cylinder head)
• 14.9. Disassembly procedure
• 14.10. Reassembly procedure
• 14.11. Servicing points
• 14.12. Parts inspection and measurement
• 14.13. Valve seat correction
• 14.14. Valve guide replacement
• 14.15. Valve stem seal replacement
• 14.16. Gear Train and Camshaft
• 14.17. Components
• 14.18. Disassembly procedure
• 14.19. Reassembly procedure
• 14.20. Servicing points
• 14.21. Parts inspection and measurement
• 14.22. Oil seal replacement (Gear case side)
• 14.23. Camshaft bushing replacement
• 14.24. Cylinder Block
• 14.25. Components
• 14.26. Disassembly procedure
• 14.27. Reassembly procedure
• 14.28. Servicing points
• 14.29. Parts inspection and measurement
• 14.30. Cylinder bore correction
• 14.31. Piston pin bushing replacement
• 14.32. Oil seal replacement (Flywheel housing side)
• 15. LUBRICATION SYSTEM
• 15.1. Lubrication System Diagram
• 15.2. Trochoid Pump Components
• 15.3. Disassembly (Reverse the procedure below for assembly)
• 15.4. Servicing Points
• 15.5. Parts Inspection and Measurement
• 16. COOLING SYSTEM
• 16.1. Cooling Water System
• 16.2. Cooling Water Pump Components
• 16.3. Disassembly (Reverse the procedure below for assembly)
• 16.4. Servicing Points
• 17. FUEL INJECTION PUMP/GOVERNOR
• 17.1. Introduction
• 17.2. Fuel Injection Pump
• 17.3. Fuel system diagram
• 17.4. External view and components
• 17.5. Disassembly procedure
• 17.6. Assembly procedure
• 17.7. Servicing points
• 18. TURBOCHARGER
• 18.1. Structure and Functions
• 18.2. Main specifications
• 18.3. Construction
• 18.4. Structural and functional outline
• 18.5. Components
• 18.6. Components
• 18.7. Service Standards and Tightening Torque
• 18.8. Service standards
• 18.9. Tightening torque
• 18.10. Periodic Inspection Procedure
• 18.11. Periodic inspection intervals
• 18.12. Inspection procedure
• 18.13. Waste gate valve adjustment procedure
• 18.14. Disassembly Procedure
• 18.15. Preparation for disassembly
• 18.16. Inspection before disassembly
• 18.17. Disassembly
• 18.18. Washing and Inspection Procedure
• 18.19. Washing
• 18.20. Inspection procedure
• 18.21. Reassembly Procedure
• 18.22. Preparation for reassembly
• 18.23. Reassembly
• 18.24. Handling after Disassembly and Reassembly
• 18.25. Instructions for turbocharger installation
• 18.26. Troubleshooting
• 18.27. Excessively exhaust smoke
• 18.28. White smoke generation
• 18.29. Sudden oil decrease
• 18.30. Decrease in output
• 18.31. Poor (slow) response (starting) of turbocharger
• 18.32. Abnormal sound or vibration
• 19. STARTING MOTOR
• 19.1. For 4D94LE/(S)4D98E
• 19.2. Specifications
• 19.3. Components
• 19.4. Troubleshooting
• 19.5. Names of parts and disassembly procedure
• 19.6. Inspection and maintenance
• 19.7. Service standards
• 19.8. Assembly
• 19.9. Characteristic test
• 20. ALTERNATOR
• 20.1. The 40A Alternator for 3D84E and Other Models
• 20.2. Components
• 20.3. Specifications
• 20.4. Wiring diagram
• 20.5. Standard output characteristics
• 20.6. Inspection
• 20.7. Troubleshooting
• 21. ELECTRIC WIRING
• 21.1. Electric Wiring Diagram
• 21.2. Precaution on Electric Wiring
• 21.3. Alternator
• 21.4. Starting motor
• 21.5. Current limiter
• 21.6. Section area and resistance of electric wire
• 22. SERVICE STANDARDS
• 22.1. Engine Tuning
• 22.2. Engine Body
• 22.3. Cylinder head
• 22.4. Gear train and camshaft
• 22.5. Cylinder block
• 22.6. Lubricating Oil System (Trochoid Pump)
• 23. TIGHTENING TORQUE FOR BOLTS AND NUTS
• 23.1. Tightening Torques for Main Bolts and Nuts
• 23.2. Tightening Torques for Standard Bolts and Nuts