Komatsu Utility 3D82AE Series Shop Manual
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Komatsu Utility 3D82AE Series Shop Manual

Komatsu Utility 3D82AE Series Shop Manual

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

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Summary of Contents for Komatsu Utility 3D82AE Series

  • Page 1 WEBMTNV000 SHOP MANUAL 3D82AE SERIES 3D84E SERIES 3D88E SERIES 4D88E SERIES 4D98E SERIES 4D106 SERIES S4D84E SERIES S4D98E SERIES S4D106 SERIES DIESEL ENGINE...
  • Page 2 WEBMTNV000 SHOP MANUAL ENGINE MODEL APPLICABLE MACHINE MODEL KOMATSU DESCRIPTION YANMAR DESCRIPTION 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...
  • Page 3 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.).
  • Page 4 SAFETY LABELS 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.
  • Page 5 Safety Precautions (1) SERVICE AREA 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. Safe / Adequate Work Area The service area should be clean, spacious, level and free from holes in the floor, to prevent “slip”...
  • Page 6 (2) WORK – WEAR (GARMENTS 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.
  • Page 7 (5) FASTENER TORQUE 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 Short Circuits Always disconnect the (-) Negative battery cable before working on the electrical system.
  • Page 8 (8) FURTHER PRECAUTIONS 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. Hot Surfaces. Do NOT touch the engine (or any of its components) during running or shortly after shutting it down.
  • Page 9 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.
  • Page 10 (2) How to Read the Explanations 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. For the removal/installation of each part, the procedure is shown with the procedural step No. in the illustration.
  • Page 11 Contents omitted in this manual Though the following jobs are omitted in the explanation in this manual, they should be conducted in actual work: Jacking up and lifting Cleaning and washing of removed parts as required Visual inspection (3) Definition of Terms [NOTICE]: Instruction whose negligence is very likely to cause an accident.
  • Page 12 CONTENTS 1. General ....................... 1 1.1 Engine Nomenclature ......................1 1.2 Specifications........................... 1 1.3 Fuel Oil, Lubricating Oil and Cooling Water................14 1.3.1 Fuel oil............................14 1.3.2 Lubricating oil .........................15 1.3.3 Cooling water .........................15 1.4 Engine External Views......................16 Structural Description ......................17 1.6 Exhaust gas emission regulation...................

  • Page 13: Table Of Contents

    4. Disassembly, Inspection and Reassembly of Engines......59 4.1 Complete disassembly and reassembly ................59 4.1.1 Introduction ..........................59 4.1.2 Special service tools.......................60 4.1.3 Complete disassembly ......................65 4.1.4 Precautions before and during reassembly ................69 4.1.5 Adjusting operation.........................69 4.2 Cylinder Head: Disassembly, Inspection and Reassembly............ 70 4.2.1 Components (2-valve cylinder head)..................70 4.2.2 Disassembly procedure:......................70 4.2.3 Reassembly procedure: ......................71...

  • Page 14: Introduction

    5. LUBRICATION SYSTEM ................ 108 5.1 Lubrication System Diagram ....................108 5.2 Trochoid Pump Components ....................109 5.3 Disassembly(Reverse the procedure below for assembly) ..........109 5.4 Servicing Points........................109 5.5 Parts Inspection and Measurement..................110 5.5.1 Trochoid pump inspection and measurement............... 110 6.

  • Page 15: Reassembly Procedure

    8.5 Washing and Inspection procedure ..................130 8.5.1 Washing ..........................130 8.5.2 Inspection procedure......................131 8.6 Reassembly Procedure ....................... 134 8.6.1 Preparation for reassembly....................134 8.6.2 Reassembly .........................134 8.7 Handling after Disassembly and Reassembly ..............137 8.7.1 Instructions for turbocharger installation................137 8.8 Troubleshooting ........................138 8.8.1 Excessively exhaust smoke ....................138 8.8.2 White smoke generation.......................138 8.8.3 Sudden oil decrease......................139...

  • Page 16: Cylinder Block

    10. ALTERNATOR..................176 10.1 The 40A Alternator for 3TNV84 and other models............. 176 10.1.1 Components ........................176 10.1.2 Specifications ........................177 10.1.3 Wiring diagram ........................177 10.1.4 Standard output characteristics ..................178 10.1.5 Inspection ...........................178 10.2 Troubleshooting ......................... 179 11. ELECTRIC WIRING ................180 11.1 Electric Wiring Diagram .....................
  • Page 17 1. General 1. General 1.1 Engine Nomenclature The engine specification class Classification Load Engine speed Available engine speed (min Constant load Constant speed 1500/1800 Variable load Variable speed 2000-3000 The engine specification class (CL or VM) is described in the specifications table. 1.2 Specifications NOTE: 1) The information described in the engine specifications tables (the next page and after) is for...
  • Page 18 1. General (1) 3TNV82A Engine name Unit 3TNV82A Engine specification class Type Vertical, in-line, 4-cycle, water-cooled diesel engine Combustion chamber Direct injection Number of cylinders Cylinder bore stroke mm mm 82 84 Displacement 1.331 Revolving 1500 1800 Continuous speed rating 12.0 Output (hp)
  • Page 19 1. General (2) 3TNV84 Engine name Unit 3TNV84 Engine specification class Type Vertical, in-line, 4-cycle, water-cooled diesel engine Combustion chamber Direct injection Number of cylinders Cylinder bore stroke mm mm 84 90 Displacement 1.496 Revolving 1500 1800 Continuous speed rating 11.3 13.5 Output...
  • Page 20 1. General (3) 3TNV84T Engine name Unit 3TNV84T Engine specification class Type Vertical, in-line, 4-cycle, water-cooled diesel engine Combustion chamber Direct injection Number of cylinders Cylinder bore stroke mm mm 84 90 Displacement 1.496 Revolving 1500 1800 Continuous speed rating 14.0 16.5 Output...
  • Page 21 1. General (4) 3TNV88 Engine name Unit 3TNV88 Engine specification class Type Vertical, in-line, 4-cycle, water-cooled diesel engine Combustion chamber Direct injection Number of cylinders Cylinder bore stroke 88 90 Displacement 1.642 Revolving 1500 1800 Continuous speed rating 12.3 14.8 Output (hp) (16.7)
  • Page 22 1. General (5) 4TNV84 Engine name Unit 4TNV84 Engine specification class Type Vertical, in-line, 4-cycle, water-cooled diesel engine Combustion chamber Direct injection Number of cylinders Cylinder bore stroke 84 90 Displacement 1.995 Revolving 1500 1800 Continuous speed Rating 14.9 17.7 Output (hp) (20.3)
  • Page 23 1. General (6) 4TNV84T Engine name Unit 4TNV84T Engine specification class Type Vertical, in-line, 4-cycle, water-cooled diesel engine Combustion chamber Direct injection Number of cylinders Cylinder bore stroke mm mm 84 90 Displacement 1.995 Revolving 1500 1800 Continuous speed rating 19.1 24.3 Output...
  • Page 24 1. General (7) 4TNV88 Engine name Unit 4TNV88 Engine specification class Type Vertical, in-line, 4-cycle, water-cooled diesel engine Combustion chamber Direct injection Number of cylinders Cylinder bore stroke mm mm 88 90 Displacement 2.190 Revolving 1500 1800 Continuous speed rating 16.4 19.6 Output...
  • Page 25 1. General (8) 4TNV94L Engine name Unit 4TNV94L Engine specification class Type Vertical, in-line, 4-cycle, water-cooled diesel engine Combustion chamber Direct injection Number of cylinders Cylinder bore stroke mm mm 94 110 Displacement 3.053 Revolving 1500 1800 Continuous speed rating 26.1 31.3 Output...
  • Page 26 1. General (9) 4TNV98 Engine name Unit 4TNV98 Engine specification class Type Vertical, in-line, 4-cycle, water-cooled diesel engine Combustion chamber Direct injection Number of cylinders Cylinder bore stroke mm mm 98 110 Displacement 3.318 Revolving 1500 1800 Continuous speed rating 30.9 36.8 Output...
  • Page 27 1. General (10) 4TNV98T Engine name Unit 4TNV98T Engine specification class Type Vertical, in-line, 4-cycle, water-cooled diesel engine Combustion chamber Direct injection Number of cylinders Cylinder bore stroke mm mm 88 110 Displacement 3.318 Revolving 1500 1800 Continuous speed rating 37.9 45.6 Output...
  • Page 28 1. General (11) 4TNV106 Engine name Unit 4TNV106 Engine specification class Type Vertical, in-line, 4-cycle, water-cooled diesel engine Combustion chamber Direct injection Number of cylinders Cylinder bore stroke mm mm 106 125 Displacement 4.412 Revolving 1500 1800 Continuous speed rating 41.2 49.3 Output...
  • Page 29 1. General (12) 4TNV106T Engine name Unit 4TNV106T Engine specification class Type Vertical, in-line, 4-cycle, water-cooled diesel engine Combustion chamber Direct injection Number of cylinders Cylinder bore stroke mm mm 106 125 Displacement 4.412 Revolving 1500 1800 Continuous speed rating 51.5 61.8 Output...
  • Page 30 1. General 1.3 Fuel Oil, Lubricating Oil and Coolant Water 1.3.1 Fuel oil IMPORTANT: Only use the recommended fuel to obtain the best engine performance and prevent damage of parts, also prevent air pollution. (1) Selection of fuel oil Use the following diesel fuels for best engine performance: BS 2869 A1 or A2 Fuels equivalent to Japanese Industrial Standard, JIS.
  • Page 31 1. General 1.3.2 Lubricating oil IMPORTANT: Use of other than the specified engine oil may cause inner parts seizure or early wear, leading to shorten the engine service life. (1) Selection of engine lube oil Use the following engine oil API classification CD or CF (Standards of America Petroleum Institute)
  • Page 32 1. General 1.4 Engine External Views...

This manual is also suitable for:

3d84e series3d88e series4d88e series4d98e series4d106 seriesS4d84e series ... Show all

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