Komatsu Utility 3D82AE Series, Shop Manual

Page 1: ...SHOP MANUAL WEBMTNV000 DIESEL ENGINE 3D82AE SERIES 3D84E SERIES 3D88E SERIES 4D88E SERIES 4D98E SERIES 4D106 SERIES S4D84E SERIES S4D98E SERIES S4D106 SERIES ...

Page 2: ...D 3D84E 5KFD SK714 5 4TNV88 K5FD 4D88E 5KFD SK815 5 4TNV88 K5FD 4D88E 5KFD SK815 5 turbo 4TNV84T K5FD S4D84E 5KFD SK818 5 4TNV88 K5FD 4D88E 5KFD SK820 5 turbo 4TNV84T K5FD S4D84E 5KFD SK1020 5 4TNV98 N2FE 4D98E 2NFE SK1020 5 turbo 4TNV98T N2FE S4D98E 2NFE SK1026 5 turbo 4TNV98T N2FE S4D98E 2NFE WB70A 1 4TNV98 N2FA 4D98E 2NFA WB98A 2 4TNV106T S2FC S4D106 2SFC WB91R 2 4TNV106 S2FA 4D106 2SFA WB93R 2...

Page 3: ...is manual assumes the standard type engine the specifications and components may partially be different from the engine installed on individual work equipment power generator pump compressor etc Please also refer to the service manual for each work equipment for details The specifications and components may be subject to change for improvement of the engine quality without notice If any modificati...

Page 4: ...he manual Sufficient consideration for safety is required in addition to the matters marked Especially for safety precautions in a repair or maintenance job not described in this manual receive instructions from a knowledgeable leader Safety marks used in this manual and their meanings are as follows DANGER indicates an imminently hazardous situation which if not avoided WILL result in death or se...

Page 5: ...us level and free from holes in the floor to prevent slip or trip and fall type accidents Bright Safely Illuminated Area The work area should be well lit or illuminated in a safe manner For work in enclosed or dark areas a drop cord should be utilized The drop cord must have a wire cage to prevent bulb breakage and possible ignition of flammable substances Safety Equipment Fire extinguisher s firs...

Page 6: ...or lifting strap as an attaching device Do not use rope serious injury may result To hold or support an engine secure the engine to a support stand test bed or test cart designed to carry the weight of the engine Do not overload this device serious injury may result Never run an engine without being properly secured to an engine support stand test bed or test cart serious injury may result Appropr...

Page 7: ...any other form of ignition away Explosion may occur causing severe personal injury Battery Electrolyte Batteries contain sulfuric acid Do NOT allow it to come in contact with clothing skin and or eyes severe burns will result 7 WASTE MANAGEMENT Observe the following instructions with regard to hazardous waste disposal Negligence of these will have a serious impact on environmental pollution concer...

Page 8: ...efore attempting to approach the unit Rotating Parts Be careful around moving rotating parts Loose clothing jewelry ties or tools may become entangled causing damage to the engine and or severe personal injury Preventing burns from scalding 1 2 Never open the radiator filler cap shortly after shutting the engine down Steam and hot water will spurt out and seriously burn you Allow the engine to coo...

Page 9: ...be used again shall be washed and cleaned sufficiently Select especially clean locations and use clean tools for disassembly of hydraulic units such as the fuel injection pump 5 Precautions for Inspection and Measurement Inspect and measure parts to be used again as required to determine whether they are reusable or not 6 Precautions for Reassembly Reassemble correct parts in correct order accordi...

Page 10: ...n the explanation for each point detailed operation method information standard and precautions are described Description Example The job contents are described in the disassembly procedure for Nos not shown in the illustration Disassembly procedure 1 Follow steps 1 to 15 of the cylinder head disassembly procedure 2 Remove the cooling water pump 3 Remove the crankshaft pulley Point 1 Operation poi...

Page 11: ...e an accident Always observe it Standard Allowable range for inspection and adjustment Limit The maximum or minimum value that must be satisfied during inspection or adjustment 4 Abbreviations Abbreviation Meaning Abbreviation Meaning Assy assembly T D C top dead center Sub Assy sub assembly B D C bottom dead center a T D C after top dead center OS oversize b T D C before top dead center US unders...

Page 12: ...aily Operation 23 2 2 2 inspection after initial 50 hours operation 25 2 2 3 Inspection every 50 hours 28 2 2 4 Inspection every 250 hours or 3 months 32 2 2 5 Inspection every 500 hours or 6 months 35 2 2 6 Inspection every 1 000 hours or one year 37 2 2 7 Inspection every 2000 hours or 2 years 46 2 3 Adjusting the no load maximum or minimum speed 49 2 4 Sensor Inspection 50 2 4 1 Oil pressure sw...

Page 13: ...easurement 76 4 2 6 Valve seat correction 80 4 2 7 Valve guide replacement 81 4 2 8 Valve stem seal replacement 82 4 3 Gear Train and Camshaft 83 4 3 1 Components 83 4 3 2 Disassembly procedure 83 4 3 3 Reassembly procedure 83 4 3 4 Servicing points 84 4 3 5 Parts inspection and measurement 87 4 3 6 Oil seal replacement Gear case side 89 4 3 7 Camshaft bushing replacement 89 4 4 Cylinder Block 90 ...

Page 14: ...system diagram 114 7 2 2 External view and components 115 7 2 3 Disassembly procedure 115 7 2 4 Assembly procedure 116 7 2 5 Servicing points 116 8 TURBOCHAGER Disassembly inspection and reassembly 118 8 1 Structure and Functions 118 8 1 1 Main specifications 118 8 1 2 Construction 118 8 1 3 Structural and functional outline 119 8 1 4 Components 120 8 2 Service Standards and Tightening Torque 121 ...

Page 15: ...response starting of turbocharger 139 8 8 6 Abnormal sound or vibration 139 9 STARTING MOTOR 140 9 1 For 4TNV94L 98 140 9 1 1 Specifications 140 9 1 2 Components 141 9 1 3 Troubleshooting 142 9 1 4 Names of parts and disassembly procedure 143 9 1 5 Inspection and Maintenance 147 9 1 6 Service standards 152 9 1 7 Assembly 153 9 1 8 Characteristic test 155 9 2 For 4TNV106 T 156 9 2 1 Specifications ...

Page 16: ...rent limiter 183 11 2 4 Section area and resistance of electric wire 184 12 SERVICE STANDARDS 185 12 1 Engine Tuning 185 12 2 Engine Body 186 12 2 1 Cylinder head 186 12 2 2 Gear train and camshaft 189 12 2 3 Cylinder block 190 12 3 Lubricating Oil System Trochoid Pump 195 12 3 1 Outside clearance of outer rotor 195 12 3 2 Side clearance of outer rotor 195 12 3 3 Inside clearance of inner rotor 19...

Page 17: ...he information described in the engine specifications tables the next page and after is for standard engine To obtain the information for the engine installed in each machine unit refer to the manual provided by the equipment manufacturer 2 Engine rating conditions are as follows SAE J1349 ISO 3046 1 Atmospheric condition Room temp 25 Atmospheric press 100 kPa 750mm Hg Relative humidity 30 Fuel te...

Page 18: ...Power take off Flywheel Direction of rotation Counterclockwise viewed from flywheel Cooling system Radiator Lubrication system Forced lubrication with trochoid pump Starting system Electric Applicable fuel Diesel oil ISO 8217 DMA BS 2869 A1 or A2 Cetane No 45 min Applicable lubricant API grade class CD or CF Total L 3 6 5 5 Lubricant capacity oil pan Effective L 1 2 2 2 Coolant water capacity engi...

Page 19: ...l side Power take off Flywheel Direction of rotation Counterclockwise viewed from flywheel Cooling system Radiator Lubrication system Forced lubrication with trochoid pump Starting system Electric Applicable fuel Diesel oil ISO 8217 DMA BS 2869 A1 or A2 Cetane No 45 min Applicable lubricant API grade class CD Total L 6 7 Lubricant capacity oil pan Effective L 1 9 Coolant water capacity engine only...

Page 20: ... off Flywheel Direction of rotation Counterclockwise viewed from flywheel Cooling system Radiator Lubrication system Forced lubrication with trochoid pump Starting system Electric Applicable fuel Diesel oil ISO 8217 DMA BS 2869 A1 or A2 cetane No 45 min Applicable lubricant API grade class CD or CF Total L 6 7 Lubricant capacity oil pan Effective L 1 9 Coolant water capacity engine only L 2 0 Over...

Page 21: ...e Power take off Flywheel Direction of rotation Counterclockwise viewed from flywheel Cooling system Radiator Lubrication system Forced lubrication with trochoid pump Starting system Electric Applicable fuel Diesel oil ISO 8217 DMA BS 2869 A1 or A2 Cetane No 45 min Applicable lubricant API grade class CD or CF Total L 4 7 7 2 Lubricant capacity oil pan Effectiv e L 1 8 3 5 Coolant water capacity e...

Page 22: ...ide Power take off Flywheel Direction of rotation Counterclockwise viewed from flywheel Cooling system Radiator Lubrication system Forced lubrication with trochoid pump Starting system Electric Applicable fuel Diesel oil ISO 8217 DMA BS 2869 A1 or A2 cetane No 45 min Applicable lubricant API grade class CD or CF Total L 7 4 Lubricant capacity oil pan Effective L 2 3 Coolant water capacity engine o...

Page 23: ... side Power take off Flywheel Direction of rotation Counterclockwise viewed from flywheel Cooling system Radiator Lubrication system Forced lubrication with trochoid pump Starting system Electric Applicable fuel Diesel oil ISO 8217 DMA BS 2869 A1 or A2 Cetane No 45 min Applicable lubricant API grade class CD or CF Total L 7 4 Lubricant capacity oil pan Effective L 3 4 Coolant water capacity engine...

Page 24: ...e Power take off Flywheel Direction of rotation Counterclockwise viewed from flywheel Cooling system Radiator Lubrication system Forced lubrication with trochoid pump Starting system Electric Applicable fuel Diesel oil ISO 8217 DMA BS 2869 A1 or A2 cetane No 45 min Applicable lubricant API grade class CD or CF Total L 5 8 8 6 Lubricant capacity oil pan Effective L 2 3 4 2 Coolant water capacity en...

Page 25: ...otation Counterclockwise viewed from flywheel Cooling system Radiator Lubrication system Forced lubrication with trochoid pump Starting system Electric Applicable fuel Diesel oil ISO 8217 DMA BS 2869 A1 or A2 Cetane No 45 min Applicable lubricant API grade class CD or CF Total L 10 2 Lubricant capacity oil pan Effective L 4 5 Coolant water capacity engine only L 4 2 Overall length mm 719 Overall w...

Page 26: ...ation Counterclockwise viewed from flywheel Cooling system Radiator Lubrication system Forced lubrication with trochoid pump Starting system Electric Applicable fuel Diesel oil ISO 8217 DMA BS 2869 A1 or A2 Cetane No 45 min Applicable lubricant API grade class CD or CF Total L 10 2 Lubricant capacity oil pan Effective L 4 5 Coolant water capacity engine only L 4 2 Overall length mm 719 Overall wid...

Page 27: ...ction of rotation Counterclockwise viewed from flywheel Cooling system Radiator Lubrication system Forced lubrication with trochoid pump Starting system Electric Applicable fuel Diesel oil ISO 8217 DMA BS 2869 A1 or A2 cetane No 45 min Applicable lubricant API grade class CD or CF Total L 10 2 Lubricant capacity oil pan Effective L 4 5 Coolant water capacity engine only L 4 2 Overall length mm 715...

Page 28: ... viewed from flywheel Cooling system Radiator Lubrication system Forced lubrication with trochoid pump Starting system Electric Applicable fuel Diesel oil ISO 8217 DMA BS 2869 A1 or A2 Cetane No 45 min Applicable lubricant API grade class CD or CF Total L 14 0 Lubricant capacity oil pan Effective L 9 0 7 5 Coolant water capacity engine only L 6 0 Overall length mm 808 776 Overall width mm 629 629 ...

Page 29: ...l Cooling system Radiator Lubrication system Forced lubrication with trochoid pump Starting system Electric Applicable fuel Diesel oil ISO 8217 DMA BS 2869 A1 or A2 Cetane No 45 min Applicable lubricant API grade class CD or CF Total L 14 0 Lubricant capacity oil pan Effective L 9 0 7 5 Coolant water capacity engine only L 6 0 Overall length mm 808 776 Overall width mm 629 628 6 Engine dimensions ...

Page 30: ...ial Standard JIS No K2204 2 Fuel cetane number should be 45 or greater 2 Fuel handling Water and dust in the fuel oil can cause operation failure Use containers which are clean inside to store fuel oil Store the containers away from rain water and dust Before supplying fuel let the fuel container rest for several hours so that water and dust in the fuel are deposited on the bottom Pump up only the...

Page 31: ... Use clean soft water and be sure to add the Long Life Coolant Antifreeze LLC in order to prevent rust built up and freezing If there is any doubt over the water guality distilled water or pre mixed coolant should be used The coolants antifreezes which are good performance for example are shown below TEXACO LONG LIFE COOLANT ANTIFREEZE both standard and pre mixed Product codes 7997 and 7998 HAVOLI...

Page 32: ...1 General 1 4 Engine External Views 16 ...