Komatsu 3D82AE Diesel Engine Workshop Repair Service Manual

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

SHOP MANUAL WEBMTNV000 APPLICABLE MACHINE MODEL ENGINE MODEL PC27R-8 3TNV82A-M5FA 3D82AE-5MFA PC35R-8 3TNV88-N5FA 3D88E-5NFA PC45R-8 4TNV88-N5FA 4D88E-5NFA PC75R-2 4TNV98-X2FB 4D98E-2XFB PW75R-2 4TNV98-X2FB 4D98E-2XFB PC95R-2 4TNV106-S2FB 4D106-2SFB PW95R-2 4TNV106-S2FB 4D1062SFB PC110R-1 4TNV106T-W2FB S4D106-2WFB PW110R-1 4TNV106T-W2FB S4D106-2WFB SK510-5 3TNV84-K5FD 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 4TNV106T-S2FA S4D106-2SFA WB97R-2 4TNV106T-S2FA S4D106-2SFA WB97S-2 4TNV106T-S2FA S4D106-2SFA WB150AWS-2 4TNV106T-S2FA S4D106-2SFA YANMAR DESCRIPTION KOMATSU DESCRIPTION

PREFACE This manual describes the service procedures for the TNV series engines of indirect injection system that have been certified by the US EPA, California ARB and/or the 97/68/EC Directive for industrial use. Please use this manual for accurate, quick and safe servicing of the said engine. Since the explanation in this 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 modification of the contents described herein becomes necessary, it will be notified in the form of correction information each time.

SAFETY LABELS z Most accidents are caused by negligence of basic safety rules and precautions. For accident prevention, it is important to avoid such causes before development to accidents. Please read this manual carefully before starting repair or maintenance to fully understand safety precautions and appropriate inspection and maintenance procedures. Attempting at a repair or maintenance job without sufficient knowledge may cause an unexpected accident. z It is impossible to cover every possible danger in repair or maintenance in the 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. z 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 serious injury. WARNING-indicates a potentially hazardous situation, which, if not avoided, COULD result in death or serious injury. CAUTION-indicates a potentially hazardous situation, which, if not avoided, MAY result in minor or moderate injury. z NOTICE-indicates that if not observed, the product performance or quality may not be guaranteed.

Safety Precautions (1) SERVICE AREA z Sufficient Ventilation Inhalation of exhaust fumes and dust particles may be hazardous to ones health. Running engines welding, sanding, painting, and polishing tasks should be only done in well ventilated areas. z Safe / Adequate Work Area The service area should be clean, spacious, level and free from holes in the floor, to prevent “slip” or “trip and fall” type accidents. z 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. z Safety Equipment Fire extinguisher(s), first aid kit and eye wash / shower station should be close at hand (or easily accessible) in case of an emergency.

(2) WORK – WEAR (GARMENTS z Safe Work Clothing Appropriate safety wear (gloves, special shoes/boots, eye/ear protection, head gear, harness’, clothing, etc.) should be used/worn to match the task at hand. Avoid wearing jewelry, unbuttoned cuffs, ties or loose fitting clothes around moving machinery. A serious accident may occur if caught in moving/rotating machinery. (3) TOOLS z Appropriate Lifting / Holding When lifting an engine, use only a lifting device (crane, jack, etc.) with sufficient lifting capacity. Do not overload the device. Use only a chain, cable, 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. z Appropriate Tools Always use tools that are designed for the task at hand. Incorrect usage of tools may result in damage to the engine and or serious personal injury. (4) GENUINE PARTS and MATERIALS z Genuine Parts Always use genuine parts or recommended parts and goods. Damage to the engine, shortened engine life and or personal injury may result.

(5) FASTENER TORQUE z Torqueing Fasteners Always follow the torque values and procedures as designated in the service manual. Incorrect values, procedures and or tools may cause damage to the engine and or personal injury. (6) Electrical z Short Circuits Always disconnect the (-) Negative battery cable before working on the electrical system. An accidental “short circuit” may cause damage, fire and or personal injury. Remember to connect the (-) Negative battery cable (back onto the battery) last. Fasten the terminals tightly. z Charging Batteries Charging wet celled batteries produces hydrogen gas. Hydrogen gas is extremely explosive. Keep sparks, open flame and any other form of ignition away. Explosion may occur causing severe personal injury. z 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 concerns. 1) 2) 3) Waste fluids such as lube oil, fuel and coolant shall be carefully put into separate sealed containers and disposed of properly. Do NOT dispose of waste materials irresponsibly by dumping them into the sewer, overland or into natural waterways. Waste materials such as oil, fuel, coolant, solvents, filter elements and batteries, must be disposed of properly according to local ordinances. Consult the local authorities or reclamation facility.

(8) FURTHER PRECAUTIONS z Fueling / Refueling Keep sparks, open flames or any other form of ignition (match, cigarette, etc.) away when fueling/refueling the unit. Fire and or an explosion may result. z Hot Surfaces. Do NOT touch the engine (or any of its components) during running or shortly after shutting it down. Scalding / serious burns may result. Allow the engine to cool down before attempting to approach the unit. z 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. z 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 cool down before attempt to open the filler cap. Securely tighten the filler cap after checking the radiator. Steam can spurt out during engine running, if tightening loose.

Precautions for Service Work (1) Precautions for Safety Read the safety precautions given at the beginning of this manual carefully and always mind safety in work. (2) Preparation for Service Work Preparation is necessary for accurate, efficient service work. Check the customer ledger file for the history of the engine. z Preceding service date z Period/operation hours after preceding service z Problems and actions in preceding service z Replacement parts expected to be required for service z Recording form/check sheet required for service (3) Preparation before Disassembly z Prepare general tools, special service tools, measuring instruments, oil, grease, non-reusable parts, and parts expected to be required for replacement. z When disassembling complicated portions, put match-marks and other marks at places not adversely affecting the function for easy reassembly. (4) Precautions in Disassembly z Each time a parts is removed, check the part installed state, deformation, damage, roughening, surface defect, etc. z Arrange the removed parts orderly with clear distinction between those to be replaced and those to be used again. z Parts to be used again shall be washed and cleaned sufficiently. z 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 z Reassemble correct parts in correct order according to the specified standards (tightening torques, and adjustment standards). Apply oil important bolts and nuts before tightening when specified. z Always use genuine parts for replacement. z Always use new oil seals, O-rings, packing and cotter pins. z Apply sealant to packing depending on the place where they are used. Apply of grease to sliding contact portions, and apply grease to oil seal lips. (7) Precautions for Adjustment and Check Use measuring instruments for adjustment to the specified service standards. How to Read this Manual (1) Range of Operation Explanation This manual explains the troubleshooting, installation/removal, replacement, disassemble/reassembly, inspection, adjustment and adjusting operation procedures for the TNV series engines with direct injection system. Refer to the manufacturer’s manual for each of the fuel injection pump, governor, starting motor and alternator except for their installation.

(2) How to Read the Explanations z An exploded view, sectional views, a system diagram, etc. are shown at the beginning of each section as required for easy understanding of the mounted states of the components. z For the removal/installation of each part, the procedure is shown with the procedural step No. in the illustration. z Precautions and key points for disassembly and reassembly of parts are described as points. In 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. z 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 point to be explained on a later page. z Operation points Disassemble: Service point for removal Reassemble: Service point for installation Disassemble-Reassemble: Service point required in both removal and installation.

Komatsu 3D82AE Diesel Engine Workshop Repair Service Manual

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