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Komatsu TNV Series Diesel Engine Service Repair Shop Manual - WEBMTNV000
This service repair workshop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the products and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity
APPLICABLE MODELS :
3D82AE SERIES
3D84E SERIES
3D88E SERIES
4D88E SERIES
4D98E SERIES
4D106 SERIES
S4D84E SERIES
S4D98E SERIES
S4D106 SERIES
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
TABLE OF CONTENTS :
1. General
2. Inspection and Adjustment
3. TROUBLESHOOTING
4. Disassembly, Inspection and Reassembly of Engines
5. LUBRICATION SYSTEM
6. COOLING SYSTEM
7. FUEL INJECTION PUMP/GOVERNOR
8. TURBOCHAGER: Disassembly, inspection and reassembly
9. STARTING MOTOR
10. ALTERNATOR
11. ELECTRIC WIRING
12. SERVICE STANDARDS
13. TIGHTENING TORQUE for BOLTS and NUTS
MANUAL SPECIFICATION :
File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : WEBMTNV000
Total pages : 280
This (OEM) Komatsu Shop Manual has detailed illustrations as well as step by step instructions, It is 100 percents complete and intact. they are specifically written for the do-it-yourself-er as well as the experienced mechanic. With step by step instruction & highly detailed exploded pictures & diagrams to show you how to complete the required job correctly & efficiently Using. Provides step-by-step instructions based on the complete dis-assembly of the machine. It is this level of detail, along with hundreds of photos and illustrations, that guide the reader through each service and repair procedure. Complete download comes in pdf format which can work under all PC based windows operating system and Mac also, All pages are printable. Using this repair manual is an inexpensive way to keep your vehicle working properly.
This page sometime can be found use following keyword : service manual, repair manual, workshop manual, technical manual, owner manual, maintenance manual, operating manual, parts manual. Please make sure you read and understand the title of this manual before decided to buy.
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COVER
1. General
1.1 Engine Nomenclature
1.2 Specifications
1.3 Fuel Oil, Lubricating Oil and Coolant Water
1.3.1 Fuel oil
1.3.2 Lubricating oil
1.3.3 Coolant water
1.4 Engine External Views
1.5 Structural Description
1.6 Exhaust gas emission regulation
1.6.1 The Emission Standard in USA
1.6.2 Engine identification
1.6.3 Guarantee Conditions for the EPA Emission Standard
2. Inspection and Adjustment
2.1 Periodic Maintenance Schedule
2.2 Periodic Inspection and Maintenance Procedure
2.2.1 Check before Daily Operation
2.2.2 inspection after initial 50 hours operation
2.2.3 Inspection every 50 hours
2.2.4 Inspection every 250 hours or 3 months
2.2.5 Inspection every 500 hours or 6 months
2.2.6 Inspection every 1,000 hours or one year
2.2.7 Inspection every 2000 hours or 2 years
2.3 Adjusting the no-load maximum or minimum speed
2.4 Sensor Inspection
2.4.1 Oil pressure switch
2.4.2 Thermo switch
2.5 Water leak check in cooling water system
2.6 Radiator cap inspection
2.7 Thermostat Inspection
2.8 Adjusting Operation
2.9 Long storage
3. TROUBLESHOOTING
3.1 Preparation before troubleshooting
3.2 Quick Reference Table for Troubleshooting
3.3 Troubleshooting by measuring Compression Pressure
4. Disassembly, Inspection and Reassembly of Engines
4.1 Complete disassembly and reassembly
4.1.1 Introduction
4.1.2 Special service tools
4.1.3 Complete disassembly
4.1.4 Precautions before and during reassembly
4.1.5 Adjusting operation
4.2 Cylinder Head: Disassembly, Inspection and Reassembly
4.2.1 Components (2-valve cylinder head)
4.2.2 Disassebly procedure:
4.2.3 Reassembly procedure:
4.2.4 Servicing points
4.2.5 Parts Inspection and measurement
4.2.6 Valve seat correction
4.2.7 Valve guide replacement
4.2.8 Valve stem seal replacement
4.3 Gear Train and Camshaft
4.3.1 Components
4.3.2 Disassembly procedure:
4.3.3 Reassembly procedure:
4.3.4 Servicing points
4.3.5 Parts inspection and measurement
4.3.6 Oil seal replacement (Gear case side)
4.3.7 Camshaft bushing replacement
4.4 Cylinder Block
4.4.1 Components
4.4.2 Disassembly procedure:
4.4.3 Reassembly procedure:
4.4.4 Servicing points
4.4.5 Parts inspection and measurement
4.4.6 Cylinder bore correction
4.4.7 Piston pin bushing replacement
4.4.8 Oil seal replacement (Flywheel housing side)
5. LUBRICATION SYSTEM
5.1 Lubrication System Diagram
5.2 Trochoid Pump Components
5.3 Disassembly(Reverse the procedure below for assembly)
5.4 Servicing Points
5.5 Parts Inspection and Measurement
5.5.1 Trochoid pump inspection and measurement
6. COOLING SYSTEM
6.1 Cooling Water System
6.2 Cooling Water Pump Components
6.3 Disassembly (Reverse the procedure below for assembly)
6.4 Servicing Points
7. FUEL INJECTION PUMP/GOVERNOR
7.1 Introduction
7.2 Fuel Injection Pump
7.2.1 Fuel system diagram
7.2.2 External view and components
7.2.3 Disassembly procedure:
7.2.4 Assembly procedure
7.2.5 Servicing points
8. TURBOCHAGER: Disassembly, inspection and reassembly
8.1 Structure and Functions
8.1.1 Main specifications
8.1.2 Construction
8.1.3 Structural and functional outline
8.1.4 Components
8.2 Service Standards and Tightening Torque
8.2.1 Service standards
8.2.2 Tightening torque
8.3 Periodic Inspection Procedure
8.3.1 Periodic inspection intervals
8.3.2 Inspection procedure
8.3.3 Waste gate valve adjustment procedure
8.4 Disassembly Procedure
8.4.1 Preparation for disassembly
8.4.2 Inspection before disassembly
8.4.3 Disassembly
8.5 Washing and Inspection procedure
8.5.1 Washing
8.5.2 Inspection procedure
8.6 Reassembly Procedure
8.6.1 Preparation for reassembly
8.6.2 Reassembly
8.7 Handling after Disassembly and Reassembly
8.7.1 Instructions for turbocharger installation
8.8 Troubleshooting
8.8.1 Excessively exhaust smoke
8.8.2 White smoke generation
8.8.3 Sudden oil decrease
8.8.4 Decrease in output
8.8.5 Poor (slow) response (starting) of turbocharger
8.8.6 Abnormal sound or vibration
9. STARTING MOTOR
9.1 For 4TNV94L/ 98
9.1.1 Specifications
9.1.2 Components
9.1.3 Troubleshooting
9.1.4 Names of parts and disassembly procedure
9.1.5 Inspection and Maintenance
9.1.6 Service standards
9.1.7 Assembly
9.1.8 Characteristic test
9.2 For 4TNV106(T)
9.2.1 Specifications
9.2.2 Congiguration drawing
9.2.3 Troubleshooting
9.2.4 Component names and disassembly procedure
9.2.5 Disassembly procedure
9.2.6 Inspection and maintenance
9.2.7 Assembly
9.2.8 Adjustment
9.2.9 Service standards
10. ALTERNATOR
10.1 The 40A Alternator for 3TNV84 and other models
10.1.1 Components
10.1.2 Specifications
10.1.3 Wiring diagram
10.1.4 Standard output characteristics
10.1.5 Inspection
10.1.6 Troubleshooting
11. ELECTRIC WIRING
11.1 Electric Wiring Diagram
11.2 PRECAUTION ON ELECTRIC WIRING
11.2.1 Alternator
11.2.2 Starter
11.2.3 Current limiter
11.2.4 Section area and resistance of electric wire
12. SERVICE STANDARDS
12.1 Engine Tuning
12.2 Engine Body
12.2.1 Cylinder head
12.2.2 Gear train and camshaft
12.2.3 Cylinder block
12.3 Lubricating Oil System (Trochoid Pump)
13. TIGHTENING TORQUE for BOLTS and NUTS
13.1 Tightening Torques for Main Bolts and Nuts
13.2 Tightening Torques for Standard Bolts and Nuts
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APPLICABLE MODELS :
3D82AE SERIES
3D84E SERIES
3D88E SERIES
4D88E SERIES
4D98E SERIES
4D106 SERIES
S4D84E SERIES
S4D98E SERIES
S4D106 SERIES
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
TABLE OF CONTENTS :
1. General
2. Inspection and Adjustment
3. TROUBLESHOOTING
4. Disassembly, Inspection and Reassembly of Engines
5. LUBRICATION SYSTEM
6. COOLING SYSTEM
7. FUEL INJECTION PUMP/GOVERNOR
8. TURBOCHAGER: Disassembly, inspection and reassembly
9. STARTING MOTOR
10. ALTERNATOR
11. ELECTRIC WIRING
12. SERVICE STANDARDS
13. TIGHTENING TORQUE for BOLTS and NUTS
MANUAL SPECIFICATION :
File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : WEBMTNV000
Total pages : 280
This (OEM) Komatsu Shop Manual has detailed illustrations as well as step by step instructions, It is 100 percents complete and intact. they are specifically written for the do-it-yourself-er as well as the experienced mechanic. With step by step instruction & highly detailed exploded pictures & diagrams to show you how to complete the required job correctly & efficiently Using. Provides step-by-step instructions based on the complete dis-assembly of the machine. It is this level of detail, along with hundreds of photos and illustrations, that guide the reader through each service and repair procedure. Complete download comes in pdf format which can work under all PC based windows operating system and Mac also, All pages are printable. Using this repair manual is an inexpensive way to keep your vehicle working properly.
This page sometime can be found use following keyword : service manual, repair manual, workshop manual, technical manual, owner manual, maintenance manual, operating manual, parts manual. Please make sure you read and understand the title of this manual before decided to buy.
-
COVER
1. General
1.1 Engine Nomenclature
1.2 Specifications
1.3 Fuel Oil, Lubricating Oil and Coolant Water
1.3.1 Fuel oil
1.3.2 Lubricating oil
1.3.3 Coolant water
1.4 Engine External Views
1.5 Structural Description
1.6 Exhaust gas emission regulation
1.6.1 The Emission Standard in USA
1.6.2 Engine identification
1.6.3 Guarantee Conditions for the EPA Emission Standard
2. Inspection and Adjustment
2.1 Periodic Maintenance Schedule
2.2 Periodic Inspection and Maintenance Procedure
2.2.1 Check before Daily Operation
2.2.2 inspection after initial 50 hours operation
2.2.3 Inspection every 50 hours
2.2.4 Inspection every 250 hours or 3 months
2.2.5 Inspection every 500 hours or 6 months
2.2.6 Inspection every 1,000 hours or one year
2.2.7 Inspection every 2000 hours or 2 years
2.3 Adjusting the no-load maximum or minimum speed
2.4 Sensor Inspection
2.4.1 Oil pressure switch
2.4.2 Thermo switch
2.5 Water leak check in cooling water system
2.6 Radiator cap inspection
2.7 Thermostat Inspection
2.8 Adjusting Operation
2.9 Long storage
3. TROUBLESHOOTING
3.1 Preparation before troubleshooting
3.2 Quick Reference Table for Troubleshooting
3.3 Troubleshooting by measuring Compression Pressure
4. Disassembly, Inspection and Reassembly of Engines
4.1 Complete disassembly and reassembly
4.1.1 Introduction
4.1.2 Special service tools
4.1.3 Complete disassembly
4.1.4 Precautions before and during reassembly
4.1.5 Adjusting operation
4.2 Cylinder Head: Disassembly, Inspection and Reassembly
4.2.1 Components (2-valve cylinder head)
4.2.2 Disassebly procedure:
4.2.3 Reassembly procedure:
4.2.4 Servicing points
4.2.5 Parts Inspection and measurement
4.2.6 Valve seat correction
4.2.7 Valve guide replacement
4.2.8 Valve stem seal replacement
4.3 Gear Train and Camshaft
4.3.1 Components
4.3.2 Disassembly procedure:
4.3.3 Reassembly procedure:
4.3.4 Servicing points
4.3.5 Parts inspection and measurement
4.3.6 Oil seal replacement (Gear case side)
4.3.7 Camshaft bushing replacement
4.4 Cylinder Block
4.4.1 Components
4.4.2 Disassembly procedure:
4.4.3 Reassembly procedure:
4.4.4 Servicing points
4.4.5 Parts inspection and measurement
4.4.6 Cylinder bore correction
4.4.7 Piston pin bushing replacement
4.4.8 Oil seal replacement (Flywheel housing side)
5. LUBRICATION SYSTEM
5.1 Lubrication System Diagram
5.2 Trochoid Pump Components
5.3 Disassembly(Reverse the procedure below for assembly)
5.4 Servicing Points
5.5 Parts Inspection and Measurement
5.5.1 Trochoid pump inspection and measurement
6. COOLING SYSTEM
6.1 Cooling Water System
6.2 Cooling Water Pump Components
6.3 Disassembly (Reverse the procedure below for assembly)
6.4 Servicing Points
7. FUEL INJECTION PUMP/GOVERNOR
7.1 Introduction
7.2 Fuel Injection Pump
7.2.1 Fuel system diagram
7.2.2 External view and components
7.2.3 Disassembly procedure:
7.2.4 Assembly procedure
7.2.5 Servicing points
8. TURBOCHAGER: Disassembly, inspection and reassembly
8.1 Structure and Functions
8.1.1 Main specifications
8.1.2 Construction
8.1.3 Structural and functional outline
8.1.4 Components
8.2 Service Standards and Tightening Torque
8.2.1 Service standards
8.2.2 Tightening torque
8.3 Periodic Inspection Procedure
8.3.1 Periodic inspection intervals
8.3.2 Inspection procedure
8.3.3 Waste gate valve adjustment procedure
8.4 Disassembly Procedure
8.4.1 Preparation for disassembly
8.4.2 Inspection before disassembly
8.4.3 Disassembly
8.5 Washing and Inspection procedure
8.5.1 Washing
8.5.2 Inspection procedure
8.6 Reassembly Procedure
8.6.1 Preparation for reassembly
8.6.2 Reassembly
8.7 Handling after Disassembly and Reassembly
8.7.1 Instructions for turbocharger installation
8.8 Troubleshooting
8.8.1 Excessively exhaust smoke
8.8.2 White smoke generation
8.8.3 Sudden oil decrease
8.8.4 Decrease in output
8.8.5 Poor (slow) response (starting) of turbocharger
8.8.6 Abnormal sound or vibration
9. STARTING MOTOR
9.1 For 4TNV94L/ 98
9.1.1 Specifications
9.1.2 Components
9.1.3 Troubleshooting
9.1.4 Names of parts and disassembly procedure
9.1.5 Inspection and Maintenance
9.1.6 Service standards
9.1.7 Assembly
9.1.8 Characteristic test
9.2 For 4TNV106(T)
9.2.1 Specifications
9.2.2 Congiguration drawing
9.2.3 Troubleshooting
9.2.4 Component names and disassembly procedure
9.2.5 Disassembly procedure
9.2.6 Inspection and maintenance
9.2.7 Assembly
9.2.8 Adjustment
9.2.9 Service standards
10. ALTERNATOR
10.1 The 40A Alternator for 3TNV84 and other models
10.1.1 Components
10.1.2 Specifications
10.1.3 Wiring diagram
10.1.4 Standard output characteristics
10.1.5 Inspection
10.1.6 Troubleshooting
11. ELECTRIC WIRING
11.1 Electric Wiring Diagram
11.2 PRECAUTION ON ELECTRIC WIRING
11.2.1 Alternator
11.2.2 Starter
11.2.3 Current limiter
11.2.4 Section area and resistance of electric wire
12. SERVICE STANDARDS
12.1 Engine Tuning
12.2 Engine Body
12.2.1 Cylinder head
12.2.2 Gear train and camshaft
12.2.3 Cylinder block
12.3 Lubricating Oil System (Trochoid Pump)
13. TIGHTENING TORQUE for BOLTS and NUTS
13.1 Tightening Torques for Main Bolts and Nuts
13.2 Tightening Torques for Standard Bolts and Nuts
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1 file (32.1MB)
