Komatsu 68E-88E Series Diesel Engine Shop Manual SEBM011501 – PDF DOWNLOAD

Komatsu 68E-88E Series Diesel Engine Shop Manual SEBM011501 – PDF DOWNLOAD

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Komatsu 68E-88E Series Diesel Engine Shop Manual SEBM011501 – PDF DOWNLOAD

Language : English
Pages : 204
Downloadable : Yes
File Type : PDF
Size: 6.05 MB

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Komatsu 68E-88E Series Diesel Engine Shop Manual SEBM011501 – PDF DOWNLOAD

The Komatsu 68E-88E Series Diesel Engine Shop Manual SEBM011501 is a comprehensive guide that provides detailed information on the repair and maintenance of the 68E and 88E series diesel engines. The manual is designed for use by mechanics and technicians who are responsible for servicing and repairing the engines.

• The manual begins with an overview of the 68E and 88E series diesel engines, including their specifications, design features, and performance characteristics. This section provides a detailed description of the engine’s construction and operation, as well as an overview of the various components that make up the engine.
• The manual then provides detailed instructions on the disassembly, inspection, repair, and reassembly of the various components of the 68E and 88E series engines. This section covers topics such as the cylinder block, cylinder head, crankshaft, pistons, connecting rods, camshaft, and timing gears.
• The cylinder block section provides detailed instructions on the removal and installation of the cylinder block, as well as instructions for inspection, repair, and reassembly of various cylinder block components, such as the cylinder liners and main bearings. The cylinder head section covers the inspection, repair, and replacement of various cylinder head components, such as valves, springs, and guides. The crankshaft section provides instructions on the inspection, repair, and replacement of various crankshaft components, such as the main and connecting rod bearings. The piston section covers the inspection, repair, and replacement of various piston components, such as rings and wrist pins. The connecting rod section provides instructions on the inspection, repair, and replacement of various connecting rod components, such as bearings and bolts. The camshaft and timing gears section covers the inspection, repair, and replacement of various camshaft and timing gear components, such as bearings, gears, and chains.
• The manual also includes a section on troubleshooting, which provides detailed instructions on how to diagnose and fix common problems that may occur during the operation of the 68E and 88E series engines. This section includes a list of common symptoms, possible causes, and recommended solutions for each problem.
• In addition to these repair and maintenance procedures, the manual includes several important safety sections. These cover topics such as engine safety, electrical safety, and hydraulic safety, and provide detailed instructions on how to handle emergencies and prevent accidents and injuries.
• Overall, the Komatsu 68E-88E Series Diesel Engine Shop Manual SEBM011501 is an essential resource for mechanics and technicians who are responsible for the repair and maintenance of these powerful engines. It provides detailed information on how to disassemble, inspect, repair, and reassemble the engine’s various components, as well as important safety information to help prevent accidents and injuries.

TABLE OF CONTENTS:

Komatsu 68E-88E Series Diesel Engine Shop Manual SEBM011501 – PDF DOWNLOAD

COVER……………………………………………………………………………………… 1
CONTENTS…………………………………………………………………………………… 2
1. SPECIFICATIONS AND PERFORMANCE…………………………………………………………….. 7
1.1 2D68E………………………………………………………………………………. 8
1.2 3D68E………………………………………………………………………………. 9
1.3 3D74E………………………………………………………………………………. 10
1.4 3D78AE……………………………………………………………………………… 11
1.5 3D82AE……………………………………………………………………………… 12
1.6 3D82E………………………………………………………………………………. 13
1.7 3D84E………………………………………………………………………………. 14
1.8 3D88E………………………………………………………………………………. 15
1.9 4D82E………………………………………………………………………………. 16
1.10 4D84E……………………………………………………………………………… 17
1.11 4D88E……………………………………………………………………………… 18
1.12 S3D84E…………………………………………………………………………….. 19
1.13 S4D84E…………………………………………………………………………….. 20
2. CROSS SECTIONAL VIEWS…………………………………………………………………….. 21
2.1 SPECIAL SWIRL PRE-COMBUSTION CHAMBER SYSTEM (INDIRECT INJECTION SYSTEM)……………………. 22
2.2 DIRECT INJECTION SYSTEM………………………………………………………………. 24
3. COOLING WATER, LUBRICATING OIL AND FUEL OIL…………………………………………………. 26
3.1 COOLING WATER……………………………………………………………………….. 27
3.2 LUBRICATING OIL……………………………………………………………………… 28
3.3 FUEL OIL……………………………………………………………………………. 30
4. TROUBLESHOOTING………………………………………………………………………….. 32
4.1 TROUBLE CAUSES AND REMEDIES…………………………………………………………… 33
4.2 TROUBLE DIAGNOSIS THROUGH MEASUREMENT OF COMPRESSION PRESSURE…………………………….. 37
5. SPECIAL SERVICE TOOLS AND MEASURING INSTRUMENTS……………………………………………… 38
5.1 SPECIAL SERVICE TOOLS………………………………………………………………… 39
5.2 MEASURING INSTRUMENTS………………………………………………………………… 42
6. MEASUREMENT, INSPECTION AND ADJUSTMENT……………………………………………………… 46
6.1 MEASURING THE COMPRESSION PRESSURE…………………………………………………….. 47
6.2 ADJUSTING THE VALVE HEAD CLEARANCE…………………………………………………….. 49
6.3 CHECKING THE V-BELT TENSION…………………………………………………………… 50
6.4 MEASURING AND CHECKING THE INJECTION PRESSURE AND SPRAY PATTERNS OF THE FUEL INJECTION VALVE…. 51
6.5 CHECKING AND ADJUSTING THE FUEL INJECTION TIMING………………………………………… 55
6.6 ADJUSTING THE NO-LOAD MAXIMUM (OR MINIMUM) REVOLUTIONS…………………………………… 58
6.7 CHECKING THE COOLING WATER SYSTEM AND RADIATOR FOR WATER LEAKAGE………………………….. 58
6.8 CHECKING THE BATTERY…………………………………………………………………. 59
6.9 CHECKING THE SENSORS…………………………………………………………………. 62
6.10 CHECKING THE OIL COOLER……………………………………………………………… 63
6.11 CHECKING THE PISTON COOLING NOZZLE……………………………………………………. 64
7. MEASURING PROCEDURES, SERVICE DATA AND CORRECTIVE ACTION……………………………………… 65
7.1 CYLINDER HEAD……………………………………………………………………….. 66
7.2 CYLINDER BLOCK………………………………………………………………………. 74
7.3 VALVE ROCKER ARM…………………………………………………………………….. 78
7.4 PISTON AND PISTON RING……………………………………………………………….. 81
7.5 CONNECTING ROD………………………………………………………………………. 87
7.6 CAMSHAFT……………………………………………………………………………. 92
7.7 CRANKSHAFT………………………………………………………………………….. 95
7.8 GEARS………………………………………………………………………………. 98
7.9 TROCHOID PUMP………………………………………………………………………..100
8. DISASSEMBLY AND REASSEMBLY…………………………………………………………………102
8.1 DISASSEMBLY………………………………………………………………………….103
8.2 PRECAUTIONS BEFORE AND DURING REASSEMBLY………………………………………………..108
9. SERVICE DATA……………………………………………………………………………..113
9.1 CYLINDER HEAD………………………………………………………………………..114
9.2 CYLINDER BLOCK……………………………………………………………………….115
9.3 VALVE ROCKER ARM……………………………………………………………………..115
9.4 PISTON………………………………………………………………………………116
9.5 PISTON RING………………………………………………………………………….117
9.6 CONNECTING ROD……………………………………………………………………….118
9.7 CAMSHAFT…………………………………………………………………………….118
9.8 CRANKSHAFT…………………………………………………………………………..119
9.9 SIDE GAP AND BACKLASH…………………………………………………………………119
9.10 OTHERS……………………………………………………………………………..120
10. TIGHTENING TORQUE………………………………………………………………………..121
10.1 MAIN BOLT/NUT……………………………………………………………………….122
10.2 STANDARD BOLT AND NUT………………………………………………………………..123
11. FUEL INJECTION PUMP FOR INDIRECT INJECTION SYSTEM……………………………………………124
11.1 EXPLODED VIEW (YPFR TYPE)…………………………………………………………….125
11.2 DISASSEMBLY…………………………………………………………………………126
11.3 INSPECTION………………………………………………………………………….128
11.4 REASSEMBLY………………………………………………………………………….130
12. FUEL INJECTION PUMP FOR DIRECT INJECTION SYSTEM……………………………………………..132
12.1 EXPLODED VIEW (YPES TYPE)…………………………………………………………….133
12.2 SPECIAL SERVICE TOOLS FOR DISASSEMBLY AND REASSEMBLY…………………………………….135
12.3 DISASSEMBLY…………………………………………………………………………136
12.4 INSPECTION………………………………………………………………………….141
12.5 REASSEMBLY………………………………………………………………………….143
13. GOVERNOR………………………………………………………………………………..148
13.1 EXPLODED VIEWS OF GOVERNOR FOR INDIRECT INJECTION SYSTEM…………………………………149
13.2 EXPLODED VIEWS OF GOVERNOR FOR DIRECT INJECTION SYSTEM…………………………………..151
13.3 DISASSEMBLY…………………………………………………………………………153
13.4 INSPECTION………………………………………………………………………….159
13.5 REASSEMBLY………………………………………………………………………….161
14. TURBOCHARGER…………………………………………………………………………….165
14.1 SPECIFICATIONS………………………………………………………………………166
14.2 CONSTRUCTION………………………………………………………………………..167
14.3 WASTE GATE VALVE ADJUSTING METHOD……………………………………………………..169
14.4 EXPLODED VIEW OF TURBOCHARGER (WITH WASTE GATE)…………………………………………171
14.5 TIGHTENING TORQUE……………………………………………………………………172
14.6 SERVICE STANDARDS……………………………………………………………………172
15. SERVICE INFORMATION FOR CARB ULG REGULATION…………………………………………………173
15.1 LIMITING THE HIGH IDLE AND LOW IDLE ADJUSTMENT SCREW…………………………………….174
15.2 LIMITING THE FUEL VOLUME LIMITER SCREW…………………………………………………175
16. ATTACHED DRAWING…………………………………………………………………………176
16.1 EXPLODED VIEWS OF ENGINE COMPONENTS……………………………………………………177
16.2 EXPLODED VIEWS OF ENGINE COMPONENTS……………………………………………………179
20. EPA CERTIFIED ENGINE……………………………………………………………………..181
20.1 APPLICABLE MACHINE, SERIAL NUMBER (EPA CERTIFIED ENGINE)…………………………………182
20.2 EPA CERTIFICATION PLATE ATTACHING LOCATION……………………………………………..183
20.3 DIFFERENCES WITH THE CURRENT PRODUCTION MODEL…………………………………………..184
20.4 FUEL INJECTION TIMING ADJUSTMENT………………………………………………………185
20.5 SECIFICATIONS……………………………………………………………………….196