Komatsu 82E-98E Series Diesel Engine Shop Manual SEBM035103

Description

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

• 1. COVER
• 2. CONTENTS
• 3. GENERAL
• 3.1. SPECIFICATIONS
• 3.2. ENGINE EXTERNAL VIEWS
• 3.3. STRUCTURAL DESCRIPTION
• 4. INSPECTION ANG ADJUSTMENT
• 4.1. PERIODIC MAINTENANCE SCHEDULE
• 4.2. PERIODIC INSPECTION AND MAINTENANCE PROCEDURE
• 4.2.1. CHECK BEFORE DAILY OPERATION
• 4.2.2. INSPECTION AFTER INITIAL 50 HOURS OPERATION
• 4.2.3. INSPECTION EVERY 50 HOURS
• 4.2.4. INSPECTION EVERY 250 HOURS OR 3 MONTHS
• 4.2.5. INSPECTION EVERY 500 HOURS OR 6 MONTHS
• 4.2.6. INSPECTION EVERY 1000 HOURS OR ONE YEAR
• 4.2.7. INSPECTION EVERY 2000 HOURS OR 2 YEARS
• 4.3. ADJUSTING THE NOLOAD MAXIMUM OR MINIMUM SPEED
• 4.4. SENSOR INSPECTION
• 4.4.1. OIL PRESSURE SWITCH
• 4.4.2. THERMO SWITCH
• 4.5. WATER LEAK CHECK IN COOLING WATER SYSTEM
• 4.6. RADIATOR CAP INSPECTION
• 4.7. THERMOSTAT INSPECTION
• 4.8. ADJUSTING OPERATION
• 4.9. LONG STORAGE
• 5. TROUBLESHOOTING
• 5.1. PREPARATION BEFORE TROUBLESHOOTING
• 5.2. QUICK REFERENCE TABLE FOR TROUBLESHOOTING
• 5.3. TROUBLESHOOTING BY MEASURING COMPRESSION PRESSURE
• 6. DISASSEMBLY, INSPECTION AND REASSEMBLY OF ENGINES
• 6.1. COMPLETE DISASSEMBLY AND REASSEMBLY
• 6.1.1. INTRODUCTION
• 6.1.2. SPECIAL SERVICE TOOLS
• 6.1.3. COMPLETE DISASSEMBLY
• 6.1.4. PRECAUTIONS BEFORE AND DURING REASSEMBLY
• 6.1.5. ADJUSTING OPERATION
• 6.2. CYLINDER HAED DISASSEMBLY, INSPECTION AND REASSEMBLY
• 6.2.1. COMPONENTS(2VALVE CYLINDER HAED)
• 6.2.2. DISASSEMBLY PROCEDURE
• 6.2.3. REASSEMBLY PROCEDURE
• 6.2.4. SERVICING POINTS
• 6.2.5. PARTS INSPECTION AND MEASUREMENT
• 6.2.6. VALVE SEAT CORRECTION
• 6.2.7. VALVE GUIDE REPLACEMENT
• 6.2.8. VALVE STEM SEAL REPLACEMENT
• 6.3. GEAR TRAIN AND CAMSHAFT
• 6.3.1. COMPONENTS
• 6.3.2. DISASSEMBLY PROCEDURE
• 6.3.3. REASSEMBLY PROCEDURE
• 6.3.4. SERVICING POINTS
• 6.3.5. PARTS INSPECTION AND MEASUREMENT
• 6.3.6. OIL SEAL REPLACEMENT (GEAR CASE SIDE)
• 6.3.7. CAMSHAFT BUSHING REPLACEMENT
• 6.4. CYLINDER BLOCK
• 6.4.1. COMPONENTS
• 6.4.2. DISASSEMBLY PROCEDURE
• 6.4.3. REASSEMBLY PROCEDURE
• 6.4.4. SERVICING POINTS
• 6.4.5. PARTS INSPECTION AND MEASUREMENT
• 6.4.6. CYLINDER BORE CORRECTION
• 6.4.7. PISTON PIN BUSHING REPLACEMENT
• 6.4.8. OIL SEAL REPLACEMENT (FLYWHEEL HOUSING SIDE)
• 7. LUBRICATION SYSTEM
• 7.1. LUBRICATION SYSTEM DIAGRAM
• 7.2. TROCHOID PUMP COMPONENTS
• 7.3. DISASSEMBLY (REVERSE THE PROCEDURE BELOW FOR ASSEMBLY)
• 7.4. SERVICING POINTS
• 7.5. PARTS INSPECTION AND MEASUREMENT
• 8. COOLING SYSTEM
• 8.1. COOLING WATER SYSTEM
• 8.2. COOLING WATER PUMP COMPONENTS
• 8.3. DISASSEMBLY (REVERSE THE PROCEDURE BELOW FOR ASSEMBLY)
• 8.4. SERVICING POINTS
• 9. FUEL INJECTION PUMP/GOVERNOR
• 9.1. INTRODUCTION
• 9.2. FUEL INJECTION PUMP
• 9.2.1. FUEL SYSTEM DIAGRAM
• 9.2.2. EXTERNAL VIEW AND COMPONENTS
• 9.2.3. DISASSEMBLY PROCEDURE
• 9.2.4. ASSEMBLY PROCEDURE
• 9.2.5. SERVICING POINTS
• 10. TURBOCHARGER
• 10.1. STRUCTURE AND FUNCTIONS
• 10.1.1. MAIN SPECIFICATIONS
• 10.1.2. CONSTRUCTION
• 10.1.3. STRUCTURAL AND FUNCTIONAL OUTLINE
• 10.1.4. COMPONENTS
• 10.1.5. COMPONENTS
• 10.2. SERVICE STANDARDS AND TIGHTENING TORQUE
• 10.2.1. SERVICE STANDARDS
• 10.2.2. TIGHTENING TORQUE
• 10.3. PERIODIC INSPECTION PROCEDURE
• 10.3.1. PERIODIC INSPECTION INTERVALS
• 10.3.2. INSPECTION PROCEDURE
• 10.3.3. WASTE GATE VALVE ADJUSTMENT PROCEDURE
• 10.4. DISASSEMBLY PROCEDURE
• 10.4.1. PREPARATION FOR DISASSEMBLY
• 10.4.2. INSPECTION BEFORE DISASSEMBLY
• 10.4.3. DISASSEMBLY
• 10.5. WASHING AND INSPECTION PROCEDURE
• 10.5.1. WASHING
• 10.5.2. INSPECTION PROCEDURE
• 10.6. REASSEMBLY PROCEDURE
• 10.6.1. PREPARATION FOR REASSEMBLY
• 10.6.2. REASSEMBLY
• 10.7. HANDING AFTER DISASSEMBLY AND REASSEMBLY
• 10.7.1. INSTRUCTIONS FOR TURBOCHARGER INSTALLATION
• 10.8. TROUBLESHOOTING
• 10.8.1. EXCESSIVELY EXHAUST SMOKE
• 10.8.2. WHITE SMOKE GENERATION
• 10.8.3. SUDDEN OIL DECREASE
• 10.8.4. DECREASE IN OUTPUT
• 10.8.5. POOR (SLOW) RESPONSE (STARTING) OF TURBOCHARGER
• 10.8.6. ABNORMAL SOUND OR VIBRATION
• 11. STARTING MOTOR
• 11.1. FOR 4D94LE/(S)4D98E
• 11.1.1. SPECIFICATIONS
• 11.1.2. COMPONENTS
• 11.1.3. TROUBLESHOOTING
• 11.1.4. NAMES OF PARTS AND DISASSEMBLY PROCEDURE
• 11.1.5. INSPECTION AND MAINTENANCE
• 11.1.6. SERVICE STANDARDS
• 11.1.7. ASSEMBLY
• 11.1.8. CHARACTERISTIC TEST
• 12. ALTERNATOR
• 12.1. THE 40A ALTERNATOR FOR 3D84E AND OTHER MODELS
• 12.1.1. COMPONENTS
• 12.1.2. SPECIFICATIONS
• 12.1.3. WIRING DIAGRAM
• 12.1.4. STANDARD OUTPUT CHARACTERISTICS
• 12.1.5. INSPECTION
• 12.1.6. TROUBLESHOOTING
• 13. ELECTRIC WIRING
• 13.1. ELECTRIC WIRING DIAGRAM
• 13.2. PRECAUTION ON ELECTRIC WIRING
• 13.2.1. ALTERNATOR
• 13.2.2. STARTING MOTOR
• 13.2.3. CURRENT LIMITER
• 13.2.4. SECTION AREA AND RESISTANCE OF ELECTRIC WIRE
• 14. SERVICE STANDARDS
• 14.1. ENGINE TUNING
• 14.2. ENGINE BODY
• 14.2.1. CYLINDER HEAD
• 14.2.2. GEAR TRAIN AND CAMSHAFT
• 14.2.3. CYLINDER BLOCK
• 14.3. LUBRICATING OIL SYSTEM (TROCHOID PUMP)
• 15. TIGHTENING TORQUE FOR BOLTS AND NUTS
• 15.1. TIGHTENING TORQUES FOR MAIN BOLTS AND NUTS
• 15.2. TIGHTENING TORQUES FOR STANDARD BOLTS AND NUTS