Complete service repair manual with Electrical Wiring Diagrams for Komatsu Diesel Engines 68E, 74E, 78E, 82E, 84E, 88E, 94E, 98E Series, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

Komatsu 68E, 74E, 78E, 82E, 84E, 88E, 94E, 98E Series Diesel Engines workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

SEBM011501 - 68E, 74E, 78E, 82E, 84E, 88E Series Diesel Engine Shop Manual.pdf
SEBM013001 - 94E, 98E Series Diesel Engine Shop Manual.pdf
SEBM035103 - 82E, 84E, 88E, 94E, 98E Series Diesel Engine Shop Manual.pdf
SEN04211-03 - 82E-6, 84E-6, 88E-6, 94E-6, 98E-6 Series Diesel Engine Shop Manual.pdf

PRODUCT DETAILS:
Total Pages: 927 pages
File Format: PDF
Language: English

MAIN SECTIONS
2. CROSS SECTIONAL VIEWS... 2-1
3. COOLING WATER, LUBRICATING OIL AND FUEL OIL ... 3-1
4. TROUBLESHOOTING ... 4-1
5. SPECIAL SERVICE TOOLS AND MEASURING INSTRUMENTS ... 5-1
6. MEASUREMENT, INSPECTION AND ADJUSTMENT ... 6-1
7. MEASURING PROCEDURES, SERVICE DATA AND CORRECTIVE ACTION... 7-1
8. DISASSEMBLY AND REASSEMBLY ... 8-1
9. SERVICE DATA ... 9-1
10. TIGHTENING TORQUE ... 10-1
11. FUEL INJECTION PUMP FOR INDIRECT INJECTION SYSTEM ... 11-1
12. FUEL INJECTION PUMP FOR DIRECT INJECTION SYSTEM ... 12-1
13. GOVERNOR ... 13-1
14. TURBOCHARGER ... 14-1
15. SERVICE INFORMATION FOR CARB ULG REGULATION ... 15-1
16. ATTACHED DRAWING... 16-1
20. EPA CERTIFIED ENGINE... 20-1

SEBM011501 - 68E, 74E, 78E, 82E, 84E, 88E Series Diesel Engine Shop Manual....2
  COVER....2
  CONTENTS....3
  1. SPECIFICATIONS AND PERFORMANCE....8
    1.1 2D68E....9
    1.2 3D68E....10
    1.3 3D74E....11
    1.4 3D78AE....12
    1.5 3D82AE....13
    1.6 3D82E....14
    1.7 3D84E....15
    1.8 3D88E....16
    1.9 4D82E....17
    1.10 4D84E....18
    1.11 4D88E....19
    1.12 S3D84E....20
    1.13 S4D84E....21
  2. CROSS SECTIONAL VIEWS....22
    2.1 SPECIAL SWIRL PRE-COMBUSTION CHAMBER SYSTEM (INDIRECT INJECTION SYSTEM)....23
    2.2 DIRECT INJECTION SYSTEM....25
  3. COOLING WATER, LUBRICATING OIL AND FUEL OIL....27
    3.1 COOLING WATER....28
    3.2 LUBRICATING OIL....29
    3.3 FUEL OIL....31
  4. TROUBLESHOOTING....33
    4.1 TROUBLE CAUSES AND REMEDIES....34
    4.2 TROUBLE DIAGNOSIS THROUGH MEASUREMENT OF COMPRESSION PRESSURE....38
  5. SPECIAL SERVICE TOOLS AND MEASURING INSTRUMENTS....39
    5.1 SPECIAL SERVICE TOOLS....40
    5.2 MEASURING INSTRUMENTS....43
  6. MEASUREMENT, INSPECTION AND ADJUSTMENT....47
    6.1 MEASURING THE COMPRESSION PRESSURE....48
    6.2 ADJUSTING THE VALVE HEAD CLEARANCE....50
    6.3 CHECKING THE V-BELT TENSION....51
    6.4 MEASURING AND CHECKING THE INJECTION PRESSURE AND SPRAY PATTERNS OF THE FUEL INJECTION VALVE....52
    6.5 CHECKING AND ADJUSTING THE FUEL INJECTION TIMING....56
    6.6 ADJUSTING THE NO-LOAD MAXIMUM (OR MINIMUM) REVOLUTIONS....59
    6.7 CHECKING THE COOLING WATER SYSTEM AND RADIATOR FOR WATER LEAKAGE....59
    6.8 CHECKING THE BATTERY....60
    6.9 CHECKING THE SENSORS....63
    6.10 CHECKING THE OIL COOLER....64
    6.11 CHECKING THE PISTON COOLING NOZZLE....65
  7. MEASURING PROCEDURES, SERVICE DATA AND CORRECTIVE ACTION....66
    7.1 CYLINDER HEAD....67
    7.2 CYLINDER BLOCK....75
    7.3 VALVE ROCKER ARM....79
    7.4 PISTON AND PISTON RING....82
    7.5 CONNECTING ROD....88
    7.6 CAMSHAFT....93
    7.7 CRANKSHAFT....96
    7.8 GEARS....99
    7.9 TROCHOID PUMP....101
  8. DISASSEMBLY AND REASSEMBLY....103
    8.1 DISASSEMBLY....104
    8.2 PRECAUTIONS BEFORE AND DURING REASSEMBLY....109
  9. SERVICE DATA....114
    9.1 CYLINDER HEAD....115
    9.2 CYLINDER BLOCK....116
    9.3 VALVE ROCKER ARM....116
    9.4 PISTON....117
    9.5 PISTON RING....118
    9.6 CONNECTING ROD....119
    9.7 CAMSHAFT....119
    9.8 CRANKSHAFT....120
    9.9 SIDE GAP AND BACKLASH....120
    9.10 OTHERS....121
  10. TIGHTENING TORQUE....122
    10.1 MAIN BOLT/NUT....123
    10.2 STANDARD BOLT AND NUT....124
  11. FUEL INJECTION PUMP FOR INDIRECT INJECTION SYSTEM....125
    11.1 EXPLODED VIEW (YPFR TYPE)....126
    11.2 DISASSEMBLY....127
    11.3 INSPECTION....129
    11.4 REASSEMBLY....131
  12. FUEL INJECTION PUMP FOR DIRECT INJECTION SYSTEM....133
    12.1 EXPLODED VIEW (YPES TYPE)....134
    12.2 SPECIAL SERVICE TOOLS FOR DISASSEMBLY AND REASSEMBLY....136
    12.3 DISASSEMBLY....137
    12.4 INSPECTION....142
    12.5 REASSEMBLY....144
  13. GOVERNOR....149
    13.1 EXPLODED VIEWS OF GOVERNOR FOR INDIRECT INJECTION SYSTEM....150
    13.2 EXPLODED VIEWS OF GOVERNOR FOR DIRECT INJECTION SYSTEM....152
    13.3 DISASSEMBLY....154
    13.4 INSPECTION....160
    13.5 REASSEMBLY....162
  14. TURBOCHARGER....166
    14.1 SPECIFICATIONS....167
    14.2 CONSTRUCTION....168
    14.3 WASTE GATE VALVE ADJUSTING METHOD....170
    14.4 EXPLODED VIEW OF TURBOCHARGER (WITH WASTE GATE)....172
    14.5 TIGHTENING TORQUE....173
    14.6 SERVICE STANDARDS....173
  15. SERVICE INFORMATION FOR CARB ULG REGULATION....174
    15.1 LIMITING THE HIGH IDLE AND LOW IDLE ADJUSTMENT SCREW....175
    15.2 LIMITING THE FUEL VOLUME LIMITER SCREW....176
  16. ATTACHED DRAWING....177
    16.1 EXPLODED VIEWS OF ENGINE COMPONENTS....178
    16.2 EXPLODED VIEWS OF ENGINE COMPONENTS....180
  20. EPA CERTIFIED ENGINE....182
    20.1 APPLICABLE MACHINE, SERIAL NUMBER (EPA CERTIFIED ENGINE)....183
    20.2 EPA CERTIFICATION PLATE ATTACHING LOCATION....184
    20.3 DIFFERENCES WITH THE CURRENT PRODUCTION MODEL....185
    20.4 FUEL INJECTION TIMING ADJUSTMENT....186
    20.5 SECIFICATIONS....197
SEBM013001 - 94E, 98E Series Diesel Engine Shop Manual....206
  COVER....206
  CONTENTS....207
  1. GENERAL....212
    1.1 SPECIFICATIONS....213
    1.2 FUEL OIL, LUBRICATING OIL AND COOLING WATER....215
    1.3 ENGINE EXTERNAL VIEWS....217
    1.4 STRUCTURAL DESCRIPTION....219
    1.5 HOW TO READ THIS MANUAL....221
    1.6 PRECAUTIONS FOR SERVICE WORK....223
    1.7 TIGHTENING TORQUES FOR STANDARD BOLTS AND NUTS....224
  2. TROUBLESHOOTING....225
    2.1 QUICK REFERENCE TABLE FOR TROUBLESHOOTING....226
    2.2 TROUBLESHOOTING BY MEASURING COMPRESSION PRESSURE....230
  3. INSPECTION AND ADJUSTMENT....232
    3.1 OIL INSPECTION....233
    3.2 COOLING WATER INSPECTION....233
    3.3 INSPECTING WATER LEAK FROM COOLING WATER SYSTEM AND RADIATOR....233
    3.4 FAN BELT TENSION INSPECTION AND ADJUSTMENT....234
    3.5 ADJUSTING THE VALVE CLEARANCE....235
    3.6 INSPECTING THE FUEL INJECTION NOZZLE INJECTION PRESSURE AND SPRAY PATTERN....236
    3.7 FUEL INJECTION TIMING INSPECTION AND ADJUSTMENT....239
    3.8 ADJUSTING THE NO-LOAD MAXIMUM (OR MINIMUM) REVOLUTIONS....240
    3.9 SENSOR INSPECTION....241
    3.10 BATTERY INSPECTION....242
    3.11 ADJUSTING OPERATION....244
    3.12 LONG STORAGE....245
    3.13 PERIODIC MAINTENANCE SCHEDULE....246
  4. ENGINE BODY....248
    4.1 INTRODUCTION....249
    4.2 CYLINDER HEAD....250
    4.3 GEAR TRAIN AND CAMSHAFT....259
    4.4 CYLINDER BLOCK....264
  5. LUBRICATION SYSTEM....277
    5.1 LUBRICATION SYSTEM DIAGRAM....278
    5.2 TROCHOID PUMP COMPONENTS....278
    5.3 DISASSEMBLY (REVERSE THE PROCEDURE BELOW FOR ASSEMBLY)....279
    5.4 SERVICING POINTS....279
    5.5 PARTS INSPECTION AND MEASUREMENT....280
  6. COOLING SYSTEM....281
    6.1 COOLING WATER SYSTEM....282
    6.2 COOLING WATER PUMP COMPONENTS....283
    6.3 DISASSEMBLY (REVERSE THE PROCEDURE BELOW FOR ASSEMBLY)....283
    6.4 SERVICING POINTS....283
  7. FUEL INJECTION PUMP/GOVERNOR....284
    7.1 INTRODUCTION....285
    7.2 FUEL INJECTION PUMP....285
    7.3 FUEL INJECTION NOZZLE....292
    7.4 FUEL FEED PUMP....292
    7.5 GOVERNOR....294
    7.6 SPECIAL SERVICE TOOLS FOR DISASSEMBLY/ASSEMBLY....295
  8. STARTING MOTOR....297
    8.1 SPECIFICATIONS....298
    8.2 COMPONENTS....299
    8.3 TROUBLESHOOTING....300
    8.4 NAMES OF PARTS AND DISASSEMBLY PROCEDURE....301
    8.5 INSPECTION AND MAINTENANCE....305
    8.6 SERVICE STANDARDS....311
    8.7 ASSEMBLY....312
    8.8 CHARACTERISTIC TEST....314
  9. ALTERNATOR....315
    9.1 SPECIFICATIONS....316
    9.2 SECTIONAL VIEW....317
    9.3 TROUBLESHOOTING....318
    9.4 PARTS NAMES AND DISASSEMBLY PROCEDURE....319
    9.5 INSPECTION AN OVERHAUL....322
    9.6 ASSEMBLY....326
    9.7 SERVICE STANDARDS....327
    9.8 PERFORMANCE TEST....328
  10. SPECIAL SERVICE TOOLS....329
    10.1 SPECIAL TOOLS....330
    10.2 MEASURING INSTRUMENTS....332
  11. SERVICE STANDARDS....335
    11.1 ENGINE TUNING....336
    11.2 ENGINE BODY....337
    11.3 LUBRICATING OIL SYSTEM (TROCHOID PUMP)....341
    11.4 TIGHTENING TORQUES FOR MAIN PARTS....342
  20. EPA CERTIFIED ENGINE....344
    20.1 APPLICABLE MACHINE, SERIAL NUMBER (EPA CERTIFIED ENGINE)....345
SEBM035103 - 82E, 84E, 88E, 94E, 98E Series Diesel Engine Shop Manual....346
  COVER....346
  CONTENTS....360
  1. GENERAL ....361
    1.1 SPECIFICATIONS....362
    1.2 ENGINE EXTERNAL VIEWS....374
    1.3 STRUCTURAL DESCRIPTION ....375
  2. INSPECTION ANG ADJUSTMENT....376
    2.1 PERIODIC MAINTENANCE SCHEDULE....377
    2.2 PERIODIC INSPECTION AND MAINTENANCE PROCEDURE....378
      2.2.1 CHECK BEFORE DAILY OPERATION ....378
      2.2.2 INSPECTION AFTER INITIAL 50 HOURS OPERATION ....380
      2.2.3 INSPECTION EVERY 50 HOURS ....383
      2.2.4 INSPECTION EVERY 250 HOURS OR 3 MONTHS ....387
      2.2.5 INSPECTION EVERY 500 HOURS OR 6 MONTHS ....390
      2.2.6 INSPECTION EVERY 1000 HOURS OR ONE YEAR ....392
      2.2.7 INSPECTION EVERY 2000 HOURS OR 2 YEARS ....401
    2.3 ADJUSTING THE NO-LOAD MAXIMUM OR MINIMUM SPEED....404
    2.4 SENSOR INSPECTION ....404
      2.4.1 OIL PRESSURE SWITCH....404
      2.4.2 THERMO SWITCH....404
    2.5 WATER LEAK CHECK IN COOLING WATER SYSTEM ....405
    2.6 RADIATOR CAP INSPECTION ....405
    2.7 THERMOSTAT INSPECTION ....406
    2.8 ADJUSTING OPERATION ....407
    2.9 LONG STORAGE....407
  3. TROUBLESHOOTING....408
    3.1 PREPARATION BEFORE TROUBLESHOOTING....409
    3.2 QUICK REFERENCE TABLE FOR TROUBLESHOOTING ....410
    3.3 TROUBLESHOOTING BY MEASURING COMPRESSION PRESSURE....413
  4. DISASSEMBLY, INSPECTION AND REASSEMBLY OF ENGINES....415
    4.1 COMPLETE DISASSEMBLY AND REASSEMBLY....416
      4.1.1 INTRODUCTION ....416
      4.1.2 SPECIAL SERVICE TOOLS....417
      4.1.3 COMPLETE DISASSEMBLY....422
      4.1.4 PRECAUTIONS BEFORE AND DURING REASSEMBLY....426
      4.1.5 ADJUSTING OPERATION ....426
    4.2 CYLINDER HAED: DISASSEMBLY, INSPECTION AND REASSEMBLY....427
      4.2.1 COMPONENTS(2-VALVE CYLINDER HAED)....427
      4.2.2 DISASSEMBLY PROCEDURE....427
      4.2.3 REASSEMBLY PROCEDURE....428
      4.2.4 SERVICING POINTS....429
      4.2.5 PARTS INSPECTION AND MEASUREMENT....433
      4.2.6 VALVE SEAT CORRECTION ....437
      4.2.7 VALVE GUIDE REPLACEMENT....438
      4.2.8 VALVE STEM SEAL REPLACEMENT....439
    4.3 GEAR TRAIN AND CAMSHAFT....440
      4.3.1 COMPONENTS....440
      4.3.2 DISASSEMBLY PROCEDURE....440
      4.3.3 REASSEMBLY PROCEDURE....440
      4.3.4 SERVICING POINTS....441
      4.3.5 PARTS INSPECTION AND MEASUREMENT....444
      4.3.6 OIL SEAL REPLACEMENT (GEAR CASE SIDE)....446
      4.3.7 CAMSHAFT BUSHING REPLACEMENT....446
    4.4 CYLINDER BLOCK....447
      4.4.1 COMPONENTS....447
      4.4.2 DISASSEMBLY PROCEDURE....447
      4.4.3 REASSEMBLY PROCEDURE....447
      4.4.4 SERVICING POINTS....448
      4.4.5 PARTS INSPECTION AND MEASUREMENT....452
      4.4.6 CYLINDER BORE CORRECTION ....463
      4.4.7 PISTON PIN BUSHING REPLACEMENT....464
      4.4.8 OIL SEAL REPLACEMENT (FLYWHEEL HOUSING SIDE)....464
  5. LUBRICATION SYSTEM....465
    5.1 LUBRICATION SYSTEM DIAGRAM....466
    5.2 TROCHOID PUMP COMPONENTS....467
    5.3 DISASSEMBLY (REVERSE THE PROCEDURE BELOW FOR ASSEMBLY)....467
    5.4 SERVICING POINTS....467
    5.5 PARTS INSPECTION AND MEASUREMENT....468
  6. COOLING SYSTEM ....470
    6.1 COOLING WATER SYSTEM ....471
    6.2 COOLING WATER PUMP COMPONENTS....471
    6.3 DISASSEMBLY (REVERSE THE PROCEDURE BELOW FOR ASSEMBLY)....472
    6.4 SERVICING POINTS....472
  7. FUEL INJECTION PUMP/GOVERNOR....473
    7.1 INTRODUCTION ....474
    7.2 FUEL INJECTION PUMP....474
      7.2.1 FUEL SYSTEM DIAGRAM....474
      7.2.2 EXTERNAL VIEW AND COMPONENTS....475
      7.2.3 DISASSEMBLY PROCEDURE....475
      7.2.4 ASSEMBLY PROCEDURE....476
      7.2.5 SERVICING POINTS....476
  8. TURBOCHARGER....478
    8.1 STRUCTURE AND FUNCTIONS....479
      8.1.1 MAIN SPECIFICATIONS....479
      8.1.2 CONSTRUCTION....479
      8.1.3 STRUCTURAL AND FUNCTIONAL OUTLINE....480
      8.1.4 COMPONENTS....480
      8.1.5 COMPONENTS....481
    8.2 SERVICE STANDARDS AND TIGHTENING TORQUE....482
      8.2.1 SERVICE STANDARDS....482
      8.2.2 TIGHTENING TORQUE....483
    8.3 PERIODIC INSPECTION PROCEDURE....484
      8.3.1 PERIODIC INSPECTION INTERVALS....484
      8.3.2 INSPECTION PROCEDURE....484
      8.3.3 WASTE GATE VALVE ADJUSTMENT PROCEDURE....485
    8.4 DISASSEMBLY PROCEDURE....487
      8.4.1 PREPARATION FOR DISASSEMBLY....487
      8.4.2 INSPECTION BEFORE DISASSEMBLY....488
      8.4.3 DISASSEMBLY....488
    8.5 WASHING AND INSPECTION PROCEDURE....489
      8.5.1 WASHING....489
      8.5.2 INSPECTION PROCEDURE....490
    8.6 REASSEMBLY PROCEDURE....493
      8.6.1 PREPARATION FOR REASSEMBLY....493
      8.6.2 REASSEMBLY....493
    8.7 HANDING AFTER DISASSEMBLY AND REASSEMBLY....496
      8.7.1 INSTRUCTIONS FOR TURBOCHARGER INSTALLATION ....496
    8.8 TROUBLESHOOTING....497
      8.8.1 EXCESSIVELY EXHAUST SMOKE....497
      8.8.2 WHITE SMOKE GENERATION ....497
      8.8.3 SUDDEN OIL DECREASE....498
      8.8.4 DECREASE IN OUTPUT....498
      8.8.5 POOR (SLOW) RESPONSE (STARTING) OF TURBOCHARGER....498
      8.8.6 ABNORMAL SOUND OR VIBRATION ....498
  9. STARTING MOTOR....499
    9.1 FOR 4D94LE/(S)4D98E....500
      9.1.1 SPECIFICATIONS....500
      9.1.2 COMPONENTS....501
      9.1.3 TROUBLESHOOTING ....502
      9.1.4 NAMES OF PARTS AND DISASSEMBLY PROCEDURE....503
      9.1.5 INSPECTION AND MAINTENANCE....507
      9.1.6 SERVICE STANDARDS....512
      9.1.7 ASSEMBLY....513
      9.1.8 CHARACTERISTIC TEST....515
  10. ALTERNATOR....516
    10.1 THE 40A ALTERNATOR FOR 3D84E AND OTHER MODELS....517
      10.1.1 COMPONENTS....517
      10.1.2 SPECIFICATIONS....518
      10.1.3 WIRING DIAGRAM....518
      10.1.4 STANDARD OUTPUT CHARACTERISTICS....519
      10.1.5 INSPECTION ....519
      10.1.6 TROUBLESHOOTING....520
  11. ELECTRIC WIRING....521
    11.1 ELECTRIC WIRING DIAGRAM....522
    11.2 PRECAUTION ON ELECTRIC WIRING....524
      11.2.1 ALTERNATOR....524
      11.2.2 STARTING MOTOR....525
      11.2.3 CURRENT LIMITER....526
      11.2.4 SECTION AREA AND RESISTANCE OF ELECTRIC WIRE....527
  12. SERVICE STANDARDS....528
    12.1 ENGINE TUNING....529
    12.2 ENGINE BODY....530
      12.2.1 CYLINDER HEAD ....530
      12.2.2 GEAR TRAIN AND CAMSHAFT....533
      12.2.3 CYLINDER BLOCK....534
    12.3 LUBRICATING OIL SYSTEM (TROCHOID PUMP)....539
  13. TIGHTENING TORQUE FOR BOLTS AND NUTS....540
    13.1 TIGHTENING TORQUES FOR MAIN BOLTS AND NUTS....541
    13.2 TIGHTENING TORQUES FOR STANDARD BOLTS AND NUTS....542
SEN04211-03 - 82E-6, 84E-6, 88E-6, 94E-6, 98E-6 Series Diesel Engine Shop Manual....543
  COVER....543
  00 Index and foreword....544
    Index....544
      Composition of shop manual....545
      Table of contents....546
    Foreword and general information....550
      Introduction....551
      Applicable machine model and serial number....552
      Safety Statements....553
      Safety Precautions....554
  01 Specification....576
    Specification and technical data....576
      Component identification....578
      Function of major engine components....580
      Main electronic control components and features....581
      Function of cooling system components....583
      Diesel fuel....584
        Diesel fuel specifications....584
        Filling the fuel tank....585
        Priming the fuel system....587
      Engine oil....587
        Engine oil specifications....587
        Engine oil viscosity....588
        Checking engine oil....588
        Adding engine oil....589
        Engine oil capacity (typical)....589
      Engine coolant....590
        Engine coolant specifications....591
        Filling radiator with engine coolant....591
        Engine coolant capacity (typical)....592
      Specifications....593
        Description of Model Number....593
        Engine speed specifications....593
        Engine general specifications....594
      Principal engine specifications....595
        3D82AE (– EPA Tier2)....595
        3D84E (– EPA Tier2)....596
        S3D84E (– EPA Tier2)....597
        3D88E (– EPA Tier2)....598
        4D84E (– EPA Tier2)....599
        S4D84E (– EPA Tier2)....600
        4D88E (– EPA Tier2)....601
        4D94LE (– EPA Tier2)....602
        4D98E (– EPA Tier2)....603
        S4D98E (– EPA Tier2)....604
        3D82AE-B (complies with EPA Interim Tier4)....605
        S3D84E-B (complies with EPA Interim Tier4)....606
        3D88E-U (complies with EPA Interim Tier4)....607
        3D88E-B (complies with EPA Interim Tier4)....608
        S4D84E-Z (complies with EPA Interim Tier4)....609
        4D88E-U (complies with EPA Interim Tier4)....610
        4D88E-B (complies with EPA Interim Tier4)....611
        4D98E-E (complies with EPA Interim Tier4)....612
        4D98E-Z (complies with EPA Interim Tier4)....613
        S4D98E-Z (complies with EPA Tier3)....614
      Engine service standards....615
      Tightening torques for standard bolts and nuts....616
      Abbreviations and symbols....618
        Abbreviations....618
        Symbols....618
      Unit conversions....619
        Unit prefixes....619
        Units of length....619
        Units of volume....619
        Units of mass....619
        Units of force....619
        Units of torque....619
        Units of pressure....619
        Units of power....619
        Units of temperature....619
  30 Testing and adjusting....622
    Testing and adjusting, Part 1....622
      Before you begin servicing....624
      Introduction....637
        The importance of periodic maintenance....637
        Performing periodic maintenance....637
        Komatsu replacement parts....637
        Required EPA / ARB maintenance - USA only....637
        EPA / ARB installation requirements - USA only....637
      Periodic maintenance schedule....638
      Periodic maintenance procedures....641
        After initial 50 hours of operation....641
        Every 50 hours of operation....645
        Every 250 hours of operation....648
        Every 500 hours of operation....653
        Every 1000 hours of operation....657
        Every 1500 hours of operation....660
        Every 2000 hours of operation....662
    Testing and adjusting, Part 2....664
      Before you begin servicing....666
      Introduction....669
      Cylinder head specifications....669
        Adjustment specifications....669
        Cylinder head....669
        Intake / exhaust valve and guide....670
        Push rod....672
        Rocker arm and shaft....672
        Valve spring....673
      Camshaft and timing gear train specifications....674
        Camshaft....674
        Idler gear shaft and bushing....676
        Timing gear backlash....676
      Crankshaft and piston specifications....677
        Crankshaft....677
        Thrust bearing....678
        Piston....679
        Piston ring....681
        Connecting rod....684
        Tappet....685
      Cylinder block specifications....686
        Cylinder block....686
      Special torque chart....687
        Torque for bolts and nuts....687
      Special service tools....690
      Measuring instruments....694
      2-valve cylinder head....696
        2-valve cylinder head components....696
        Components of a two-valve cylinder head....697
        Disassembly of 2-valve cylinder head....698
        Cleaning of cylinder head components....702
        Inspection of cylinder head components....702
        Reassembly of cylinder head....706
      4-valve cylinder head....711
        4-valve cylinder head components....711
        Disassembly of 4-valve cylinder head....712
        Cleaning of cylinder head components....717
        Inspection of cylinder head components....718
        Reassembly of cylinder head....723
      Measuring and adjusting valve clearance....728
        2-valve cylinder heads....729
        4-valve cylinder heads....730
      Crankshaft and camshaft components....733
        Disassembly of engine....734
        Disassembly of camshaft and timing components....735
        Disassembly of crankshaft and piston components....740
        Inspection of crankshaft and camshaft components....744
        Honing and boring....750
        Reassembly of crankshaft and piston components....751
        Reassembly of camshaft and timing components....756
        Final reassembly of engine....760
      EGR system....761
        EGR system....761
        EGR system....763
        Inspecting/cleaning EGR related components....766
    Testing and adjusting, Part 3....772
      Before you begin servicing....774
      Introduction....779
        Fuel injection pump....779
        Stop solenoid....780
        Cold start device....780
        Trochoid fuel pump....781
        Electronically controlled governor....781
      Fuel system specifications....782
        Special torque chart....782
        Test and adjustment specifications....783
      Special service tools....784
      Measuring instruments....784
      Fuel system diagram....785
      Fuel system components....786
        2-valve cylinder head....786
        4-valve cylinder head....788
      Fuel injection pump....790
        Removal of fuel injection pump....790
        Installation of fuel injection pump....795
      Checking and adjusting fuel injection timing....801
        Determining the fuel injection timing specification....801
        Checking fuel injection timing....802
        Adjusting fuel injection timing....805
      Fuel injectors....806
        Removal of fuel injectors....806
        Testing of fuel injectors....809
        Disassembly and inspection of fuel injectors....810
        Adjusting fuel injector pressure....812
        Reassembly of fuel injectors....812
        Installation of the fuel injectors....813
    Testing and adjusting, Part 4....816
      Before you begin servicing....818
      Introduction....821
      Cooling system diagram....821
      Engine coolant pump components....822
      Engine coolant system check....823
      Engine coolant pump....823
        Removal of engine coolant pump....823
        Disassembly of engine coolant pump....825
        Cleaning and inspection....825
        Reassembly of engine coolant pump....826
        Installation of engine coolant pump....827
    Testing and adjusting, Part 5....830
      Before you begin servicing....832
      Introduction....834
      Oil pump service information....834
      Lubrication system diagram....837
      Checking engine oil pressure....838
      Trochoid oil pump....838
        3D82AE to 4D88E oil pump components....838
        Disassembly of oil pump....839
        Cleaning and inspection....840
        Reassembly of oil pump....841
      Trochoid oil pump....842
        3D82AE-B, 3D88E-B, 3D88E-U, 4D88E-B, 4D88E-U, S3D84E-Z, S4D84E-Z Oil pump components....842
        Disassembly of oil pump....843
        Cleaning and inspection....843
        Reassembly of oil pump....845
      Trochoid oil pump....846
        4D94LE/98E oil pump components....846
        Disassembly of oil pump....846
        Cleaning and inspection....847
        Reassembly of oil pump....848
    Testing and adjusting, Part 6....850
      Before you begin servicing....852
      Introduction....854
      Specifications....854
        Turbocharger service information....854
      Troubleshooting....855
        Excessive exhaust smoke....855
        Generates white smoke....856
        Sudden oil decrease....856
        Decrease in output....856
        Poor (slow) response (starting) of turbocharger....856
        Abnormal sound or vibration....856
      Turbocharger components....857
      Turbocharger component functions....859
        Theory of operation....860
        Compressor side sealing mechanism....860
        Waste gate modulation....860
      Washing procedure....861
      Periodic inspection....862
        Visual inspection....862
        Inspection of rotor rotation....862
        Inspection of rotor play....862
        Removal of turbocharger....862
        Checking rotor play....863
        Waste gate valve test....863
        Waste gate actuator leak test....864
        Installation of turbocharger....864
    Testing and adjusting, Part 7....866
      Before you begin servicing....868
      Introduction....870
      Starter motor information....870
        3D82AE to 4D88E - Standard and optional....870
        4D94LE to S4D98E - Standard and optional....871
      Starter motor specifications....872
      Starter motor troubleshooting....873
      Starter motor components....874
      Starter motor....875
        Removal of starter motor....875
        Disassembly of starter motor....875
        Cleaning and inspection....877
        Reassembly of starter motor....882
        Check pinion projection length....883
        No-load test....884
        Installation of starter motor....885
    Testing and adjusting, Part 8....888
      Before you begin servicing....890
      Introduction....893
      Dynamo and alternator information....893
        3D82AE to S4D98E - Standard and optional dynamos....893
        3D82AE to S4D98E - Standard and optional alternators....893
      Alternator specifications....894
      Dynamo specifications....894
      Alternator troubleshooting....895
      Alternator components....896
      Alternator wiring diagram....897
      Alternator standard output....898
      Alternator....899
        Removal of alternator....899
        Disassembly of alternator....899
        Reassembly of alternator....901
        Installation of alternator....903
      Dynamo component location....904
      Dynamo wiring diagram....905
      Operation of dynamo....905
      Dynamo standard output....906
      Testing of dynamo....907
        Testing stator coil continuity....907
        Testing stator coil short-to-ground....907
        Testing dynamo regulated output....907
      Dynamo....907
        Removal of dynamo....907
        Disassembly of dynamo....908
        Reassembly of dynamo....908
        Installation of dynamo....909
  40 Troubleshooting....912
    Troubleshooting of mechanical system....912
      Special service tools....914
      Troubleshooting by measuring compression pressure....916
        Compression pressure measurement method....916
      Quick reference table for troubleshooting....919
        Failure Diagnostic List....920

Komatsu 68E, 74E, 78E, 82E, 84E, 88E, 94E, 98E Series Diesel Engine Repair Service Manuals