Komatsu 82E Series Install guide

00-1
SEBM035103
© 2008
All Rights Reserved
Printed in Japan 01-08 (01)
DIESEL ENGINE
(3)

00-2 82E-5 – 98E-5 SERIES
PREFACE
(2)
PREFACE
This manual describes the service procedures for the 82E – 98E series engines of indirect injection system.
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 machine. Please also refer to the shop manual for each machine for details.

82E-5 – 98E-5 SERIES 00-2-1
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00-2-2 82E-5 – 98E-5 SERIES
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82E-5 – 98E-5 SERIES 00-3
SAFETY LABELS
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 precau-
tions and appropriate inspection and maintenance procedures.
Attempting at a repair or maintenance job without sufficient knowledge may cause an unexpected accident.
• It is impossible to cover every possible danger in repair or maintenance in the manual. Sufficient consider-
ation for safety is required in addition to the matters marked . Especially for safety precautions
in a repair or maintenance job not described in this manual, receive instructions from a knowledgeable lead-
er.
• Safety marks used in this manual and their meanings are as follows:
•NOTICE – indicates that if not observed, the product performance or quality may not be guaranteed.
DANGER – indicates an imminently hazardous situation which, if not
avoided, WILL result in death or serious injury.
WARNING – indicates a potentially hazardous situation which, if not
avoided, COULD result in death or serious injury.
CAUTION – indicates a potentially hazardous situation which, if not
avoided, MAY result in minor or moderate injury.

00-4 82E-5 – 98E-5 SERIES
SAFETY PRECAUTIONS
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" or "trip and fall" type accidents.
• Bright, Safely Illuminated Area
The work area should be well lit or illuminated in a safe manner. For
work in enclosed or dark areas, a "drop cord" should be utilized. The
drop cord must have a wire cage to prevent bulb breakage and possible
ignition of flammable substances.
• Safety Equipment
Fire extinguisher(s), first aid kit and eye wash / shower station should be
close at hand (or easily accessible) in case of an emergency.

82E-5 – 98E-5 SERIES 00-5
SAFETY PRECAUTIONS
(2) WORK - WEAR (GARMENTS)
(3) TOOLS
(4) GENUINE PARTS and MATERIALS
• Safe Work Clothing
Appropriate safety wear (gloves, special shoes/boots, eye/ear protec-
tion, 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.
• Appropriate Lifting / Holding
When lifting an engine, use only a lifting device (crane, jack, etc.) with
sufficient lifting capacity. Do not overload the device. Use only a chain,
cable, or lifting strap as an attaching device. Do not use rope, serious
injury may result.
To hold or support an engine, secure the engine to a support stand, test
bed or test cart designed to carry the weight of the engine. Do not over-
load this device, serious injury may result.
Never run an engine without being properly secured to an engine sup-
port stand, test bed or test cart, serious injury may result.
• Appropriate Tools
Always use tools that are designed for the task at hand. Incorrect usage
of tools may result in damage to the engine and or serious personal
injury.
• Genuine Parts
Always use genuine KOMATSU parts or KOMATSU recommended parts
and goods. Damage to the engine, shortened engine life and or personal
injury may result.

00-6 82E-5 – 98E-5 SERIES
SAFETY PRECAUTIONS
(5) FASTENER TORQUE
(6) ELECTRICAL SYSTEM
(7) WASTE MANAGEMENT
• Torqueing Fasteners
Always follow the torque values and procedures as designated in the
shop manual. Incorrect values, procedures and or tools may cause dam-
age to the engine and or personal injury.
• Short Circuits
Always disconnect the (–) Negative battery cable before working on the
electrical system. An accidental "short circuit" may cause damage, fire
and or personal injury. Remember to connect the (–) Negative battery
cable (back onto the battery) last.
Fasten the terminals tightly.
• Charging Batteries
Charging wet celled batteries produces hydrogen gas. Hydrogen gas is
extremely explosive. Keep sparks, open flame and any other form of
ignition away. Explosion may occur causing severe personal injury.
• Battery Electrolyte
Batteries contain sulfuric acid. Do NOT allow it to come in contact with
clothing, skin and or eyes, severe burns will result.
Observe the following instructions with regard to hazardous waste disposal.
Negligence of these will have a serious impact on environmental pollution
concerns.
1) Waste fluids such as lube oil, fuel and coolant shall be carefully put into
separate sealed containers and disposed of properly.
2) Do NOT dispose of waste materials irresponsibly by dumping them into
the sewer, overland or into natural waterways.
3) Waste materials such as oil, fuel, coolant, solvents, filter elements and
batteries, must be disposed of properly according to local ordinances.
Consult the local authorities or reclamation facility.

82E-5 – 98E-5 SERIES 00-7
SAFETY PRECAUTIONS
(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. Scalding / serious burns may result. Allow
the engine to cool down before attempting to approach the unit.
• Rotating Parts
Be careful around moving/rotating parts. Loose clothing, jewelry, ties or
tools may become entangled causing damage to the engine and or
severe personal injury.
• Preventing burns from scalding
1) Never open the radiator filler cap shortly after shutting the engine
down.
Steam and hot water will spurt out and seriously burn you. Allow the
engine to cool down before attempt to open the filler cap.
2) Securely tighten the filler cap after checking the radiator.
Steam can spurt out during engine running, if tightening loose.

00-8 82E-5 – 98E-5 SERIES
PRECAUTIONS FOR SERVICE WORK
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.
• Preceding service date
• Period/operation hours after preceding service
• Problems and actions in preceding service
• Replacement parts expected to be required for service
• Recording form/check sheet required for service
3. Preparation before Disassembly
• Prepare general tools, special service tools, measuring instruments, oil, grease, non reusable parts, and
parts expected to be required for replacement.
• When disassembling complicated portions, put match marks and other marks at places not adversely
affecting the function for easy reassembly.
4. Precautions in Disassembly
• Each time a parts is removed, check the part installed state, deformation, damage, roughening, surface
defect, etc.
• Arrange the removed parts orderly with clear distinction between those to be replaced and those to be
used again.
• Parts to be used again shall be washed and cleaned sufficiently.
• Select especially clean locations and use clean tools for disassembly of hydraulic units such as the fuel
injection pump.
5. Precautions for Inspection and Measurement
Inspect and measure parts to be used again as required to determine whether they are reusable or not.
6. Precautions for Reassembly
• Reassemble correct parts in correct order according to the specified standards (tightening torques, and
adjustment standards). Apply oil important bolts and nuts before tightening when specified.
• Always use genuine parts for replacement.
• Always use new oil seals, O-rings, packings and cotter pins.
• Apply sealant to packings depending on the place where they are used. Apply of grease to sliding con-
tact portions, and apply grease to oil seal lips.
7. Precautions for Adjustment and Check
Use measuring instruments for adjustment to the specified service standards.

82E-5 – 98E-5 SERIES 00-9
HOW TO READ THIS MANUAL
HOW TO READ THIS MANUAL
1. Range of Operation Explanation
This manual explains the troubleshooting, installation/removal, replacement, disassemble/reassembly,
inspection, adjustment and adjusting operation procedures for the 82E-5 to 98E-5 series engines with direct
injection system.
Refer to the shop manual for each of the fuel injection pump, governor, starting motor and alternator except
for their installation.
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 il-
lustration.
• Precautions and key points for disassembly and reassembly of parts are described as points. In the
explanation for each point, detailed operation method, information, standard and precautions are de-
scribed.
Description Example
The job contents are described in the disassembly procedure for Nos. not shown in the illustration.
• Disassembly procedure
1) Follow steps (1) to (15) of the cylinder head disassembly procedure.
2) Remove the cooling water pump.
3) Remove the crankshaft pulley. (Point 1) i
ii
iOperation point to be explained on a later page.
• Operation points
Disassemble: Service point for removal
Reassemble: Service point for installation
Disassemble-Reassemble: Service point required in both removal and installation.

00-10 82E-5 – 98E-5 SERIES
HOW TO READ THIS MANUAL
• Contents omitted in this manual
Though the following jobs are omitted in the explanation in this manual, they should be conducted in
actual work:
1) Jacking up and lifting
2) Cleaning and washing of removed parts as required
3) Visual inspection
3. Definition of Terms
[NOTICE]: Instruction whose negligence is very likely to cause an accident. Always observe it.
Standard: Allowable range for inspection and adjustment.
Limit: The maximum or minimum value that must be satisfied during inspection or adjustment.
4. Abbreviations
Abbreviation Meaning Abbreviation Meaning
Ass’y assembly T.D.C. top dead center
Sub-Ass’y sub-assembly B.D.C. bottom dead center
A.T.D.C. after top dead center OS oversize
B.T.D.C. before top dead center US undersize
STD Standard rpm revolutions per minute
IN Intake HP Output (horsepower)
EX Exhaust T Bolt/nut tightening torque
kW Output (SI unit)

82E-5 – 98E-5 SERIES 00-11
APPLICATION CATEGORY
APPLICATION CATEGORY
★For engine application category described in Chapter 1, Specifications.
Engine Nomenclature
Application code Usage Eng. Rev. type. Revolution speed (rpm)
CL Generator drive Constant 1,500/1,800
VM General use Variable 2,000 – 2,500
4 D E —
Model
Cylinder bore (mm)
Diesel engine
Number of cylinders

00-12 82E-5 – 98E-5 SERIES
APPLICABLE MACHINE, SERIAL NUMBER
(3)
APPLICABLE MACHINE, SERIAL NUMBER
Engine Machine model Machine Serial No. Remarks
3D82AE-5M PC27MR-2 15001 and up
3D84E-5N PC30MR-2 20001 and up
3D84E-5X WA30-5 26001 and up
S3D84E-5X
WA40-3 19001 and up
WA50-3 23001 and up
S3D84E-5PBA PC35MR-2 6736 and up High altitude spec.
3D88E-5P
PC35MR-2 5001 and up
MX352 6Y6089 and up
4D88E-5X
PC40MR-2 8001 and up
PC50MR-2 5001 and up
MX502 6Y7038 and up
PC58UU-3 22001 and up
4D94LE-2Z
D20A-8 83001 and up
D20P-8 83001 and up
D20PL-8 63001 and up
D20PLL-8 63001 and up
D21A-8 83001 and up
D21P-8 83001 and up
D21PL-8 63001 and up
D21PLL-8 63001 and up
D21A-8E0 90001 and up
D21P-8E0 90001 and up

82E-5 – 98E-5 SERIES 1-1
CONTENTS
1. GENERAL............................................................................................................ 1-2
2. INSPECTION AND ADJUSTMENT ..................................................................... 2-1
3. TROUBLESHOOTING ......................................................................................... 3-1
4. DISASSEMBLY, INSPECTION AND REASSEMBLY OF ENGINES.................. 4-1
5. LUBRICATION SYSTEM..................................................................................... 5-1
6. COOLING SYSTEM............................................................................................. 6-1
7. FUEL INJECTION PUMP/GOVERNOR............................................................... 7-1
8. TURBOCHARGER............................................................................................... 8-1
9. STARTING MOTOR............................................................................................. 9-1
10. ALTERNATOR................................................................................................... 10-1
11. ELECTRIC WIRING ........................................................................................... 11-1
12. SERVICE STANDARDS .................................................................................... 12-1
13. TIGHTENING TORQUE FOR BOLTS AND NUTS............................................ 13-1

1-2 82E-5 – 98E-5 SERIES
1. GENERAL
(2)
1. GENERAL
1.1 Specifications........................................................................................................................................ 1-3
1.2 Engine External Views ........................................................................................................................ 1-51
1.3 Structural Description.......................................................................................................................... 1-52

82E-5 – 98E-5 SERIES 1-3
1. GENERAL
(2)
1.1 Specifications
3D82AE
*1 :Items may differ from the above depending on an engine installed on a machine unit.
*2 :Engine weight and dimensions without radiator
Engine name Unit 3D82AE
Engine specification class – VM
Type – Vertical, in-line, 4-cycle, water-cooled diesel engine
Combustion chamber – Direct injection
Number of cylinders – 3
Cylinder bore x stroke mm x mm 82 x 84
Displacement l(cc) 1.331 (1,331)
Continuous rating
Revolving
speed rpm –
Output kW
{HP} –
Rated output
Revolving
speed rpm 2,000 2,200 2,400 2,500 2,600 2,800 3,000
Output kW
{HP}
14.6
{19.6}
16.0
{21.5}
17.5
{23.5}
18.2
{24.5}
19.0
{25.4}
20.4
{27.4}
21.9
{29.4}
Max. no-load speed (± 25) rpm 2,180 2,375 2,570 2,675 2,780 2,995 3,180
Ignition order – 1-3-2-1(No.1 cylinder on flywheel side)
Power take off – Flywheel
Direction of rotation – Counterclockwise (viewed from flywheel)
Cooling system – Radiator
Lubrication system – Forced lubrication with trochoid pump
Starting system – Electric
Applicable fuel – Diesel oil-ISO 8217 DMA, BS 2869 A1 or A2
(Cetane No.45 min.)
Applicable lubricant – API grade class CD or CF
Lubricant capacity
(oil pan) (*1)
Tot a l l5.5
Effective l1.9
Cooling water capacity (engine only) l1.8
Engine Dimensions (*2)
(with flywheel housing) (*1)
Overall
length mm 528
Overall
width mm 489
Overall
height mm 565
Engine dry weight (*1),(*2)
(with flywheel housing) kg 128
Cooling fan (std.) (*1) mm 335 mm O/D, 6 blades pusher type F
Fan V pulley diameter (std.) (*1) mm 110 x 110

1-4 82E-5 – 98E-5 SERIES
1. GENERAL
(2)
3D84E
*1 :Items may differ from the above depending on an engine installed on a machine unit.
*2 :Engine weight and dimensions without radiator
Engine name Unit 3D84E
Engine specification class – VM
Type – Vertical, in-line, 4-cycle, water-cooled diesel engine
Combustion chamber – Direct injection
Number of cylinders – 3
Cylinder bore x stroke mm x mm 84 x 90
Displacement l(cc) 1.496 (1,496)
Continuous rating
Revolving
speed rpm –
Output kW
{HP} –
Rated output
Revolving
speed rpm 2,000 2,200 2,400 2,500 2,600 2,800 3,000
Output kW
{HP}
16.4
{22.0}
18.1
{24.3}
19.7
{26.4}
20.5
{27.5}
21.3
{28.6}
23.0
{30.9}
24.6
{33.0}
Max. no-load speed (± 25) rpm 2,180 2,400 2,590 2,690 2,810 2,995 3,210
Ignition order – 1-3-2-1(No.1 cylinder on flywheel side)
Power take off – Flywheel
Direction of rotation – Counterclockwise (viewed from flywheel)
Cooling system – Radiator
Lubrication system – Forced lubrication with trochoid pump
Starting system – Electric
Applicable fuel – Diesel oil-ISO 8217 DMA, BS 2869 A1 or A2
(Cetane No.45 min.)
Applicable lubricant – API grade class CD
Lubricant capacity
(oil pan) (*1)
Total l6.7
Effective l2.8
Cooling water capacity (engine only) l2.0
Engine dimensions (*2)
(with flywheel housing) (*1)
Overall
length mm 564
Overall
width mm 486
Overall
height mm 622
Engine dry weight (*1) ,(*2)
(with flywheel housing) kg 155
Cooling fan (std.) (*1) mm 335 mm O/D, 6 blades pusher type F
Crankshaft V pulley diameter &
Fan V pulley diameter (std.) (*1) mm 110 x 110

82E-5 – 98E-5 SERIES 1-5
1. GENERAL
(2)
S3D84E
*1 :Items may differ from the above depending on an engine installed on a machine unit.
*2 :Engine weight and dimensions without radiator
Engine name Unit S3D84E
Engine specification class – VM
Type – Vertical, in-line, 4-cycle, water-cooled diesel engine
Combustion chamber – Direct injection
Number of cylinders – 3
Cylinder bore x stroke mm x mm 84 x 90
Displacement l(cc) 1.496 (1,496)
Continuous rating
Revolving
speed rpm –
Output kW
{HP} –
Rated output
Revolving
speed rpm 2,000 2,200 2,400 2,500 2,600 2,800 3,000
Output kW
{HP}
25.0
{33.5}
26.0
{34.8}
26.8
{36.0}
29.1
{38.9}
30.9
{41.4}
Max. no-load speed (± 25) rpm 2,590 2,700 2,810 2,995 3,210
Ignition order – 1-3-2-1(No.1 cylinder on flywheel side)
Power take off – Flywheel
Direction of rotation – Counterclockwise (viewed from flywheel)
Cooling system – Radiator
Lubrication system – Forced lubrication with trochoid pump
Starting system – Electric
Applicable fuel – Diesel oil-ISO 8217 DMA, BS 2869 A1 or A2
(cetane No.45 min.)
Applicable lubricant – API grade class CD or CF
Lubricant capacity
(oil pan) (*1)
Tot a l l6.7
Effective l2.8
Cooling water capacity (engine only) l2.0
Engine dimensions (*2)
(with flywheel housing) (*1)
Overall
length mm 564
Overall
width mm 486
Overall
height mm 622
Engine dry weight (*1),(*2)
(with flywheel housing) kg 155
Cooling fan (std.) (*1) mm 350 mm O/D, 6 blades pusher type F
Crankshaft V pulley diameter &
Fan V pulley diameter (std.) (*1) mm 110 x 110

1-6 82E-5 – 98E-5 SERIES
1. GENERAL
(2)
*1 :Items may differ from the above depending on an engine installed on a machine unit.
*2 :Engine weight and dimensions without radiator
Engine name Unit S3D84E (High altitude spec.)
Engine specification class – VM
Type – Vertical, in-line, 4-cycle, water-cooled diesel engine
Combustion chamber – Direct injection
Number of cylinders – 3
Cylinder bore x stroke mm x mm 84 x 90
Displacement l(cc) 1.496 (1,496)
Continuous rating
Revolving
speed rpm –
Output kW
{HP} –
Rated output
Revolving
speed rpm 2,000 2,200 2,400 2,500 2,600 2,800 3,000
Output kW
{HP}
23.9
{32.1}
Max. no-load speed (± 25) rpm 2,590
Ignition order – 1-3-2-1(No.1 cylinder on flywheel side)
Power take off – Flywheel
Direction of rotation – Counterclockwise (viewed from flywheel)
Cooling system – Radiator
Lubrication system – Forced lubrication with trochoid pump
Starting system – Electric
Applicable fuel – Diesel oil-ISO 8217 DMA, BS 2869 A1 or A2
(cetane No.45 min.)
Applicable lubricant – API grade class CD or CF
Lubricant capacity
(oil pan) (*1)
Total l6.7
Effective l2.8
Cooling water capacity (engine only) l2.0
Engine dimensions (*2)
(with flywheel housing) (*1)
Overall
length mm 564
Overall
width mm 486
Overall
height mm 622
Engine dry weight (*1),(*2)
(with flywheel housing) kg 155
Cooling fan (std.) (*1) mm 350 mm O/D, 6 blades pusher type F
Crankshaft V pulley diameter &
Fan V pulley diameter (std.) (*1) mm 110 x 110