Komatsu 3D82AE Series Manuals

Manuals and User Guides for Komatsu 3D82AE Series. We have 1 Komatsu 3D82AE Series manual available for free PDF download: Shop Manual

Komatsu 3D82AE Series Shop Manual

Komatsu 3D82AE Series Shop Manual (280 pages)

Brand: Komatsu | Category: Engine | Size: 33 MB

Table of Contents

Section 1

12
- Table of Contents
  12
- General
  17
- Engine Nomenclature
  17
- Specifications
  17
- Fuel Oil, Lubricating Oil and Cooling Water
  30
- Fuel Oil
  30
- Lubricating Oil
  31
- Engine External Views
  32
- Structural Description
  33
- Exhaust Gas Emission Regulation
  34
- The Emission Standard in USA
  34
- Engine Identification
  35
- Guarantee Conditions for the EPA Emission Standard
  36
- Periodic Maintenance Schedule
  38
- Inspection and Adjustment
  38
- Periodic Inspection and Maintenance Procedure
  39
- Check before Daily Operation
  39
- Inspection after Initial 50 Hours Operation
  41
- Inspection Every 50 Hours
  44
- Inspection Every 250 Hours or 3 Months
  48
- Inspection Every 500 Hours or 6 Months
  51
- Inspection Every 1,000 Hours or One Year
  53
- Inspection Every 2000 Hours or 2 Years
  62
- Adjusting the No-Load Maximum or Minimum Speed
  65
- Sensor Inspection
  66
- Oil Pressure Switch
  66
- Thermo Switch
  66
- Water Leak Check in Cooling Water System
  66
- Radiator Cap Inspection
  67
- Thermostat Inspection
  67
- Adjusting Operation
  68
- Long Storage
  68
- Troubleshooting
  69
- Preparation before Troubleshooting
  69
- Quick Reference Table for Troubleshooting
  70
- Troubleshooting by Measuring Compression Pressure
  73
- Disassembly, Inspection and Reassembly of Engines
  75
- Complete Disassembly and Reassembly
  75
- Introduction
  75
- Special Service Tools
  76
- Complete Disassembly
  81
- Adjusting Operation
  85
- Precautions before and During Reassembly
  85
- Cylinder Head: Disassembly, Inspection and Reassembly
  86
- Components (2-Valve Cylinder Head)
  86
- Disassembly Procedure
  86
- Reassembly Procedure
  87
- Servicing Points
  88
- Parts Inspection and Measurement
  92
- Valve Seat Correction
  96
- Valve Guide Replacement
  97
- Valve Stem Seal Replacement
  98
- Gear Train and Camshaft
  99
- Components
  99
- Disassembly Procedure
  99
- Reassembly Procedure
  99
- Servicing Points
  100
- Parts Inspection and Measurement
  103
- Oil Seal Replacement (Gear Case Side)
  105
- Camshaft Bushing Replacement
  105
- Cylinder Block
  106
- Components
  106
- Disassembly Procedure
  106
- Reassembly Procedure
  106
- Servicing Points
  107
- Parts Inspection and Measurement
  111
- Cylinder Bore Correction
  122
- Piston Pin Bushing Replacement
  123
- Oil Seal Replacement (Flywheel Housing Side)
  123
- Lubrication System Diagram
  124
- Lubrication System
  124
- Trochoid Pump Components
  125
- Disassembly(Reverse the Procedure below for Assembly)
  125
- Servicing Points
  125
- Parts Inspection and Measurement
  126
- Trochoid Pump Inspection and Measurement
  126
- Cooling System
  128
- Cooling Water System
  128
- Cooling Water Pump Components
  128
- Disassembly (Reverse the Procedure below for Assembly)
  129
- Servicing Points
  129
- Fuel Injection Pump
  130
- Fuel System Diagram
  130
- Introduction
  130
- Fuel Injection Pump/Governor
  130
- External View and Components
  131
- Disassembly Procedure
  131
- Assembly Procedure
  132
- Servicing Points
  132
- TURBOCHAGER: Disassembly, Inspection and Reassembly
  134
- Structure and Functions
  134
- Main Specifications
  134
- Construction
  134
- Structural and Functional Outline
  135
- Components
  136
- Service Standards and Tightening Torque
  137
- Service Standards
  137
- Tightening Torque
  138
- Periodic Inspection Procedure
  139
- Periodic Inspection Intervals
  139
- Inspection Procedure
  140
- Waste Gate Valve Adjustment Procedure
  141
- Disassembly Procedure
  143
- Preparation for Disassembly
  143
- Inspection before Disassembly
  144
- Disassembly
  144
- Washing and Inspection Procedure
  146
- Washing
  146
- Inspection Procedure
  147
- Reassembly Procedure
  150
- Preparation for Reassembly
  150
- Reassembly
  150
- Instructions for Turbocharger Installation
  153
- Handling after Disassembly and Reassembly
  153
- White Smoke Generation
  154
- Troubleshooting
  154
- Excessively Exhaust Smoke
  154
- Sudden Oil Decrease
  155
- Decrease in Output
  155
- Poor (Slow) Response (Starting) of Turbocharger
  155
- Abnormal Sound or Vibration
  155
- Starting Motor
  156
- For 4TNV94L/ 98
  156
- Specifications
  156
- Components
  157
- Troubleshooting
  158
- Names of Parts and Disassembly Procedure
  159
- Inspection and Maintenance
  163
- Service Standards
  168
- Assembly
  169
- Characteristic Test
  171
- For 4TNV106(T)
  172
- Specifications
  172
- Congiguration Drawing
  172
- Troubleshooting
  173
- Component Names and Disassembly Procedure
  174
- Disassembly Procedure
  175
- Inspection and Maintenance
  183
- Assembly
  189
- Adjustment
  190
- Service Standards
  191
- Components
  192
- Alternator
  192
- The 40A Alternator for 3TNV84 and Other Models
  192
- Specifications
  193
- Wiring Diagram
  193
- Standard Output Characteristics
  194
- Inspection
  194
- Troubleshooting
  195
- Electric Wiring
  196
- Electric Wiring Diagram
  196
- Precaution on Electric Wiring
  197
- Alternator
  197
- Starter
  198
- Current Limiter
  199
- Section Area and Resistance of Electric Wire
  200
- Service Standards
  201
- Engine Tuning
  201
- Engine Body
  202
- Cylinder Head
  202
- Gear Train and Camshaft
  205
- Cylinder Block
  206
- Lubricating Oil System (Trochoid Pump)
  211
- Outside Clearance of Outer Rotor
  211
- Side Clearance of Outer Rotor
  211
- Inside Clearance of Inner Rotor
  211
- Rotor Shaft Clearance
  211
- TIGHTENING TORQUE for BOLTS and NUTS
  212
- Tightening Torques for Main Bolts and Nuts
  212
- Tightening Torques for Standard Bolts and Nuts
  213
Section 2

216
- For Safe Servicing
  219
- Warning Symbols
  219
- Safety Precautions
  220
- General Information
  222
- Outline of MP Pump
  222
- Specifications
  223
- Outline of Fuel Injection Pump
  224
- Construction of MP-Pump
  225
- Fuel Injection Part
  225
- Governor Part
  226
- Delivery Part
  235
- Feed Pump
  236
- Function of Component
  236
- Structure and Functions
  238
- Timer Mechanism
  238
- Cold Start Device)
  239
- Cold Starting Advancer
  239
- Disassembly
  240
- Disassembly ,Reassembly and Inspection
  240
- Separating the Pump Body from the Governor Body
  240
- Disassembling the Hydraulic Head
  241
- Separating the Governor Weight CMP
  241
- Separating Hydraulic Head CMP
  243
- Separating the Cam Shaft
  243
- Disassembling the Hydraulic Head CMP
  245
- Disassembling the Governor
  246
- Re-Assembling the Hydraulic Head
  247
- Reassembly
  247
- Re-Assembling Cam Shaft
  248
- Install the Hydraulic Head CMP
  252
- Assembling the Hydraulic Head
  253
- Re-Assembling the Governor
  257
- Combining Governor and Pump Bodies
  258
- Adjustment of Fuel Injection Pump and Governor
  260
- Preparations
  260
- Bottom Clearance Adjustment(Fuel Injection Timing)
  262
- The Bottom Clearance Adjusting Value and the Cam Classification
  263
- Adjustment of Fuel Limit Bolt
  264
- Adjustment of Governor
  264
- Adjustment of no Load Max. Engine Speed
  264
- Adjustment of Torque-Rise Point
  264
- Adjustment of Reverse Angleich
  265
- Adjustment of Staring Injection Amount
  266
- Checking the Injection Stop
  266
- Fuel Injection Nozzle
  267
- Functioning of Fuel Injection Nozzle
  267
- Type/Construction of Fuel Injection Nozzle
  267
- Fuel Injection Nozzle Disassembly
  268
- Fuel Injection Nozzle Inspection
  269
- Washing
  269
- Nozzle Inspection
  270
- Adjusting Fuel Injection Nozzle
  271
- Adjusting Opening Pressure
  271
- Fuel Injection Nozzle Reassembly
  271
- Injection Test
  272
- Troubleshooting
  273
- Troubleshooting of Fuel Injection Pump
  273

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