TNV Series Diesel Engine WEBMTNV000 SAMPLE Komatsu

WEBMTNV000
SHOP MANUAL
3D82AE SERIES
3D84E SERIES
3D88E SERIES
4D88E SERIES
4D98E SERIES
4D106 SERIES
S4D84E SERIES
S4D98E SERIES
S4D106 SERIES
DIESEL ENGINE
WEBMTNV000
SHOP MANUAL
APPLICABLE ENGINE MODEL

MACHINE MODEL YANMAR DESCRIPTION KOMATSU DESCRIPTION
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
SK815-5 turbo 4TNV84T-K5FD S4D84E-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
PREFACE
This manual describes the service procedures for the TNV series engines of indirect injection system
that have been certified by the US EPA, California ARB and/or the 97/68/EC Directive for industrial use.
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 work equipment (power generator, pump,
compressor, etc.). Please also refer to the service manual for each work equipment for details.
The specifications and components may be subject to change for improvement of the engine quality
without notice. If any modification of the contents described herein becomes necessary, it will be
notified in the form of correction information each time.
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 precautions 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
consideration 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 leader.
Safety marks used in this manual and their meanings are as follows:
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.
NOTICE-indicates that if not observed, the product performance or quality may not be
guaranteed.
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.
(2) WORK – WEAR (GARMENTS
Safe Work Clothing

Appropriate safety wear (gloves, special shoes/boots, eye/ear
protection, 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.
(3) TOOLS
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
overload this device, serious injury may result.
Never run an engine without being properly secured to an engine support
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.
(4) GENUINE PARTS and MATERIALS
Genuine Parts
Always use genuine parts or recommended parts
and goods. Damage to the engine, shortened engine life and or
personal injury may result.
(5) FASTENER TORQUE
Torqueing Fasteners
Always follow the torque values and procedures as designated in the
service manual. Incorrect values, procedures and or tools may cause
damage to the engine and or personal injury.
(6) Electrical
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.
(7) WASTE MANAGEMENT

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.
(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.
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, packing and cotter pins.
Apply sealant to packing depending on the place where they are used. Apply of grease to sliding
contact portions, and apply grease to oil seal lips.
(7) Precautions for Adjustment and Check

Use measuring instruments for adjustment to the specified service standards.
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 TNV series engines with direct
injection system.
Refer to the manufacturer’s 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
illustration.
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 described.
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) Operation 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.
Contents omitted in this manual
Though the following jobs are omitted in the explanation in this manual, they should be conducted
in actual work:
3) Jacking up and lifting
4) Cleaning and washing of removed parts as required
5) 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

Assy assembly T.D.C. top dead center
Sub-Assy 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 Min-1 revolutions per minute
IN Intake PS Output (metric horsepower)
EX Exhaust T Bolt/nut tightening torque

CONTENTS
1. General ....................................................................................................... 1
1.1 Engine Nomenclature .............................................................................................................. 1
1.2 Specifications........................................................................................................................... 1
1.3 Fuel Oil, Lubricating Oil and Cooling Water........................................................................... 14
1.3.1 Fuel oil....................................................................................................................................14
1.3.2 Lubricating oil .........................................................................................................................15
1.3.3 Cooling water .........................................................................................................................15
1.4 Engine External Views........................................................................................................... 16
1.5 Structural Description ............................................................................................................. 17
1.6 Exhaust gas emission regulation........................................................................................... 18
1.6.1 The Emission Standard in USA ..............................................................................................18
1.6.2 Engine identification ...............................................................................................................19
1.6.3 Guarantee Conditions for the EPA Emission Standard ...........................................................20
2. Inspection and Adjustment........................................................................ 22

2.1 Periodic Maintenance Schedule ............................................................................................ 22
2.2 Periodic Inspection and Maintenance Procedure .................................................................. 23
2.2.1 Check before Daily Operation ................................................................................................23
2.2.2 inspection after initial 50 hours operation ...............................................................................25
2.2.3 Inspection every 50 hours ......................................................................................................28
2.2.4 Inspection every 250 hours or 3 months ................................................................................32
2.2.5 Inspection every 500 hours or 6 months ................................................................................35
2.2.6 Inspection every 1,000 hours or one year ..............................................................................37
2.2.7 Inspection every 2000 hours or 2 years .................................................................................46
2.3 Adjusting the no-load maximum or minimum speed.............................................................. 49
2.4 Sensor Inspection.................................................................................................................. 50
2.4.1 Oil pressure switch .................................................................................................................50
2.4.2 Thermo switch ........................................................................................................................50
2.5 Water leak check in cooling water system............................................................................. 50
2.6 Radiator cap inspection ......................................................................................................... 51
2.7 Thermostat Inspection ........................................................................................................... 51
2.8 Adjusting Operation ............................................................................................................... 52
2.9 Long storage.......................................................................................................................... 52
3. TROUBLESHOOTING .............................................................................. 53
3.1 Preparation before troubleshooting ....................................................................................... 53
3.2 Quick Reference Table for Troubleshooting .......................................................................... 54
3.3 Troubleshooting by measuring Compression Pressure......................................................... 57
4. Disassembly, Inspection and Reassembly of Engines.............................. 59
4.1 Complete disassembly and reassembly ................................................................................ 59
4.1.1 Introduction ............................................................................................................................59
4.1.2 Special service tools...............................................................................................................60
4.1.3 Complete disassembly ...........................................................................................................65
4.1.4 Precautions before and during reassembly ............................................................................69
4.1.5 Adjusting operation.................................................................................................................69
4.2 Cylinder Head: Disassembly, Inspection and Reassembly.................................................... 70
4.2.1 Components (2-valve cylinder head)......................................................................................70
4.2.2 Disassembly procedure:.........................................................................................................70
4.2.3 Reassembly procedure: .........................................................................................................71
4.2.4 Servicing points ......................................................................................................................72
4.2.5 Parts Inspection and measurement........................................................................................76
4.2.6 Valve seat correction ..............................................................................................................80
4.2.7 Valve guide replacement ........................................................................................................81
4.2.8 Valve stem seal replacement..................................................................................................82
4.3 Gear Train and Camshaft ...................................................................................................... 83
4.3.1 Components ...........................................................................................................................83
4.3.5 Parts inspection and measurement ........................................................................................87
4.3.6 Oil seal replacement (Gear case side) ...................................................................................89
4.3.7 Camshaft bushing replacement..............................................................................................89
4.4 Cylinder Block........................................................................................................................ 90
4.4.1 Components ...........................................................................................................................90
4.4.5 Parts inspection and measurement ........................................................................................95
4.4.6 Cylinder bore correction .......................................................................................................106
4.4.7 Piston pin bushing replacement ...........................................................................................107
4.4.8 Oil seal replacement (Flywheel housing side) ......................................................................107
5. LUBRICATION SYSTEM ........................................................................ 108
5.1 Lubrication System Diagram ............................................................................................... 108
5.2 Trochoid Pump Components ............................................................................................... 109
5.3 Disassembly(Reverse the procedure below for assembly) ................................................. 109
5.4 Servicing Points................................................................................................................... 109
5.5 Parts Inspection and Measurement......................................................................................110
5.5.1 Trochoid pump inspection and measurement....................................................................... 110
6. COOLING SYSTEM.................................................................................112
6.1 Cooling Water System ..........................................................................................................112
6.2 Cooling Water Pump Components .......................................................................................112
6.3 Disassembly (Reverse the procedure below for assembly) .................................................113
6.4 Servicing Points....................................................................................................................113
7. FUEL INJECTION PUMP/GOVERNOR...................................................114

7.1 Introduction ...........................................................................................................................114
7.2 Fuel Injection Pump..............................................................................................................114
7.2.1 Fuel system diagram ............................................................................................................ 114
7.2.2 External view and components.............................................................................................115
7.2.3 Disassembly procedure:....................................................................................................... 115
7.2.4 Assembly procedure............................................................................................................. 116
7.2.5 Servicing points .................................................................................................................... 116
8. TURBOCHAGER: Disassembly, inspection and reassembly.....................118

8.1 Structure and Functions........................................................................................................118
8.1.1 Main specifications ............................................................................................................... 118
8.1.2 Construction ......................................................................................................................... 118
8.1.3 Structural and functional outline ........................................................................................... 119
8.1.4 Components .........................................................................................................................120
8.2 Service Standards and Tightening Torque ........................................................................... 121
8.2.1 Service standards.................................................................................................................121
8.2.2 Tightening torque..................................................................................................................122
8.3 Periodic Inspection Procedure............................................................................................. 123
8.3.1 Periodic inspection intervals .................................................................................................123
8.3.2 Inspection procedure............................................................................................................124
8.3.3 Waste gate valve adjustment procedure ..............................................................................125
8.4 Disassembly Procedure....................................................................................................... 127
8.4.1 Preparation for disassembly .................................................................................................127
8.4.2 Inspection before disassembly .............................................................................................128
8.4.3 Disassembly .........................................................................................................................128
8.5 Washing and Inspection procedure ..................................................................................... 130
8.5.1 Washing ...............................................................................................................................130
8.5.2 Inspection procedure............................................................................................................131
8.6 Reassembly Procedure ....................................................................................................... 134
8.6.1 Preparation for reassembly...................................................................................................134
8.6.2 Reassembly .........................................................................................................................134
8.7 Handling after Disassembly and Reassembly ..................................................................... 137
8.7.1 Instructions for turbocharger installation...............................................................................137
8.8 Troubleshooting ................................................................................................................... 138
8.8.1 Excessively exhaust smoke .................................................................................................138
8.8.2 White smoke generation.......................................................................................................138
8.8.3 Sudden oil decrease.............................................................................................................139
8.8.4 Decrease in output ...............................................................................................................139
8.8.5 Poor (slow) response (starting) of turbocharger ...................................................................139
8.8.6 Abnormal sound or vibration.................................................................................................139
9. STARTING MOTOR ................................................................................ 140

9.1 For 4TNV94L/ 98 ................................................................................................................. 140
9.1.1 Specifications .......................................................................................................................140
9.1.2 Components .........................................................................................................................141
9.1.3 Troubleshooting....................................................................................................................142
9.1.4 Names of parts and disassembly procedure ........................................................................143
9.1.5 Inspection and Maintenance ................................................................................................147
9.1.7 Assembly..............................................................................................................................153
9.1.8 Characteristic test.................................................................................................................155
9.2 For 4TNV106(T) .................................................................................................................. 156
9.2.1 Specifications .......................................................................................................................156
9.2.2 Congiguration drawing .........................................................................................................156
9.2.3 Troubleshooting ....................................................................................................................157
9.2.4 Component names and disassembly procedure ..................................................................158
9.2.5 Disassembly procedure........................................................................................................159
9.2.6 Inspection and maintenance ................................................................................................167
9.2.7 Assembly..............................................................................................................................173
9.2.8 Adjustment ...........................................................................................................................174
10. ALTERNATOR....................................................................................... 176
10.1 The 40A Alternator for 3TNV84 and other models............................................................. 176
10.1.1 Components .......................................................................................................................176
10.1.2 Specifications .....................................................................................................................177
10.1.3 Wiring diagram ...................................................................................................................177
10.1.4 Standard output characteristics ..........................................................................................178
10.1.5 Inspection ...........................................................................................................................178
10.2 Troubleshooting ................................................................................................................. 179
11. ELECTRIC WIRING .............................................................................. 180

11.1 Electric Wiring Diagram ..................................................................................................... 180
11.2 PRECAUTION ON ELECTRIC WIRING............................................................................ 181
11.2.1 Alternator ............................................................................................................................181
11.2.2 Starter .................................................................................................................................182
11.2.3 Current limiter .....................................................................................................................183
11.2.4 Section area and resistance of electric wire .......................................................................184
12. SERVICE STANDARDS ....................................................................... 185

12.1 Engine Tuning.................................................................................................................... 185
12.2 Engine Body ...................................................................................................................... 186
12.2.1 Cylinder head .....................................................................................................................186
12.2.2 Gear train and camshaft .....................................................................................................189
12.2.3 Cylinder block.....................................................................................................................190
12.3 Lubricating Oil System (Trochoid Pump) ........................................................................... 195
12.3.1 Outside clearance of outer rotor .........................................................................................195
12.3.2 Side clearance of outer rotor ..............................................................................................195
12.3.3 Inside clearance of inner rotor ............................................................................................195
12.3.4 Rotor shaft clearance .........................................................................................................195
13. TIGHTENING TORQUE for BOLTS and NUTS .................................... 196

13.1 Tightening Torques for Main Bolts and Nuts ...................................................................... 196
13.2 Tightening Torques for Standard Bolts and Nuts ............................................................... 197
1. General
1. General
1.1 Engine Nomenclature
The engine specification class

Classification Load Engine speed Available engine speed (min-1)
CL Constant load Constant speed 1500/1800
VM Variable load Variable speed 2000-3000

The engine specification class (CL or VM) is described in the specifications table.
1.2 Specifications
NOTE:
1) The information described in the engine specifications tables (the next page and after) is for
"standard" engine. To obtain the information for the engine installed in each machine unit, refer
to the manual provided by the equipment manufacturer.
2) Engine rating conditions are as follows (SAE J1349, ISO 3046/1)
Atmospheric condition: Room temp. 25 , Atmospheric press. 100 kPa (750mm Hg), Relative
humidity 30%
Fuel temp: 25 (Fuel injection pump inlet)
With cooling fan, air cleaner, exhaust silencer.
After running-in hours. Output allowable deviation: 3%
1
1. General
(1) 3TNV82A
Engine name Unit 3TNV82A
Engine specification class - CL VM
Type - Vertical, in-line, 4-cycle, water-cooled diesel engine
Combustion chamber - Direct injection
Number of cylinders - 3
Cylinder bore stroke mm mm 82 84
Displacement L 1.331
Revolving
Min-1 1500 1800 -
Continuous speed
rating kW 9.9 12.0
Output -
(hp) (13.5) (16.3)
Revolving
Min-1 1500 1800 2000 2200 2400 2500 2600 2800 3000
speed
Rated output
kW 11.0 13.2 14.6 16.0 17.5 18.2 19.0 20.4 21.9
Output
(hp) (14.9) (17.9) (19.9) (21.8) (23.8) (24.8) (25.8) (27.8) (29.8)
Max. no-load speed ( 25) min-1 1600 1895 2180 2375 2570 2675 2780 2995 3180
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

Diesel oil-ISO 8217 DMA, BS 2869 A1 or A2
Applicable fuel -
(Cetane No.45 min.)
Applicable lubricant - API grade class CD or CF
Lubricant capacity Total L 3.6 5.5

(oil pan) * Effective L 1.2 2.2
Coolant water capacity
L 1.8
(engine only)
Overall
mm 553 528
Engine Dimensions ** length
(with flyw Crankshaft Overall
mm 489
V pulley diameter & width
heel housing) Overall
mm 565
height
Engine mass (dry) **
kg 138 128
(with flywheel housing)
Cooling fan (std.) mm 335 mm O/D, 6 blades pusher type
Fun V pulley diameter (std.) mm 120 90 110 110

* Engine oil capacity may differ from the above depending on an engine installed on a machine unit.
** Engine mass and dimensions without radiator
2
1. General
(2) 3TNV84
Engine name Unit 3TNV84
Revolving
Min-1 1500 1800 -
Continuous speed
rating kW 11.3 13.5
Output -
(hp) (15.3) (18.3)
Revolving
Min-1 1500 1800 2000 2200 2400 2500 2600 2800 3000
speed
Rated output
kW 12.4 14.8 16.4 18.1 19.7 20.5 21.3 23.0 24.6
Output
(hp) (16.8) (20.1) (22.3) (24.6) (26.8) (27.9) (29.0) (31.3) (33.5)

Applicable fuel -
(Cetane No.45 min.)
Applicable lubricant - API grade class CD
Lubricant capacity Total L 6.7

(oil pan) * Effective L 1.9
L 1.8
(engine only)
Overall
mm 589 564
length
Engine dimensions ** Overall
mm 486
(with flywheel housing) width
Overall
mm 622
height
kg 161 155
Crankshaft V pulley diameter &
mm 120 90 110 110
Fun V pulley diameter (std.)
3
1. General
(3) 3TNV84T
Engine name Unit 3TNV84T
Revolving
Min-1 1500 1800 -
Continuous speed
rating kW 14.0 16.5
Output -
(hp) (19.0) (22.5)
Revolving
Min-1 1500 1800 2000 2200 2400 2500 2600 2800 3000
speed
Rated output
kW 15.8 18.8 25.0 25.9 26.8 29.1 30.9
Output
(hp) (21.5) (25.5) (34.0) (35.2) (36.5) (39.5) (42.0)
Max. no-load speed ( 25) min-1 1600 1895 2590 2700 2810 2995 3210

Applicable fuel -
(cetane No.45 min.)

L 2.0
(engine only)
Overall
mm 589 564
length
mm 486
Overall
mm 622
height
kg 161 155
mm 120 90 110 110
4
1. General
(4) 3TNV88
mm
Cylinder bore stroke 88 90
mm
Revolving
Min-1 1500 1800 -
Continuous speed
rating kW 12.3 14.8
Output -
(hp) (16.7) (20.1)
Revolving
Min-1 1500 1800 2000 2200 2400 2500 2600 2800 3000
speed
Rated output
kW 13.5 16.3 18.0 19.9 21.6 22.6 23.5 25.2 27.1
Output
(hp) (18.4) (22.1) 24.5) (27.0) (29.4) (30.7) (31.9) (34.2) (36.8)

Applicable fuel -
(Cetane No.45 min.)
Total L 4.7 7.2

Lubricant capacity
(oil pan) * Effectiv
L 1.8 3.5
e
L 2.0
(engine only)
Overall
mm 589 564
length
mm 486
Overall
mm 622
height
kg 155
Cooling fan (std.) Mm 350 mm O/D, 6 blades pusher type
Mm 120 90 120 90
5
1. General
(5) 4TNV84
mm
Cylinder bore stroke 84 90
mm
Revolving
Min-1 1500 1800 -
Continuous speed
Rating kW 14.9 17.7
Output -
(hp) (20.3) (24.1)
Revolving
Min-1 1500 1800 2000 2200 2400 2500 2600 2800 3000
speed
Rated output
kW 16.4 19.5 21.9 24.1 26.3 27.4 28.5 30.7 32.9
Output
(hp) (22.3) (26.5) (29.8) (32.8) (35.8) (37.3) (38.7) 41.7) (44.7)
Ignition order - 1-3-4-2-1(No.1 cylinder on flywheel side)

Applicable fuel -
(cetane No.45 min.)

L 2.7
(engine only)
Overall
mm 683 658
length
Engine dimensions **
Overall
(with flywheel mm 498.5
width
housing)
Overall
mm 617
height
kg 183 170
mm 120 90 110 110
6
1. General
(6) 4TNV84T
Revolving
Min-1 1500 1800 -
Continuous speed
rating KW 19.1 24.3
Output -
(hp) (26.0) (33.0)
Revolving
Min-1 1500 1800 2000 2200 2400 2600 2800 3000
speed
Rated output
KW 21.3 26.9 27.9 30.5 33.5 35.7 38.6 41.2
Output
(hp) (29.0) (36.5) (38.0) (41.5) (45.5) (48.5) (52.5) (56.0)
Max. no-load speed ( 25) min-1 1600 1895 2180 2400 2590 2810 2995 3210

Applicable fuel -
(Cetane No.45 min.)

L 2.7
(engine only)
Overall
mm 683 649
length
Engine Overall
mm 498.5
dimensions ** width
Overall
mm 713
height
kg 183 170
mm 120 90 110 110
7
1. General
(7) 4TNV88
Revolving
Min-1 1500 1800 -
Continuous speed
rating kW 16.4 19.6
Output -
(hp) (22.3) (26.7)
Revolving
Min-1 1500 1800 2000 2200 2400 2500 2600 2800 3000
speed
Rated output
kW 18.0 21.6 24.1 26.5 28.8 30.1 31.3 33.7 35.4
Output
(hp) (24.5) (29.4) (32.7) (36.0) (39.2) (40.9) (42.5) (45.8) (48.1)

Applicable fuel -
(cetane No.45 min.)
Lubricant capacity Total L 5.8 8.6

L 2.7
(engine only)
Overall
mm 683 658
ength
mm 498.5
(with wheel housing) width
Overall
mm 618
height
kg 183 170
mm 120 90 110 110
8
1. General
(8) 4TNV94L
Engine name Unit 4TNV94L
Revolving
Min-1 1500 1800 -
Continuous speed
rating kW 26.1 31.3
Output -
(hp) (35.5) (42.5)
Revolving
Min-1 1500 1800 2000 2200 2400 2500
speed
Rated output
kW 29.1 34.6 35.3 38.2 41.6 43.0
Output
(hp) (39.5) (47.0) (48.0) (52.0) (56.5) (58.5)
Max. no-load speed ( 25) min-1 1600 1895 2180 2400 2590 2700

Applicable fuel -
(Cetane No.45 min.)

L 4.2
(engine only)
Overall
mm 719
length
mm 498
Overall
mm 717
height
Engine mass (dry) ** 245 235
kg
(with flywheel housing) (equivalent to SAE#3) (equivalent to SAE#4)
mm 130 130
9
1. General
(9) 4TNV98
Revolving
Min-1 1500 1800 -
Continuous speed
rating kW 30.9 36.8
Output -
(hp) (42.0) (50.0)
Revolving
Min-1 1500 1800 2000 2200 2400 2500
speed
Rated output
kW 34.6 41.2 41.9 45.6 49.3 51.1
Output
(hp) (47.0 (56.0) (57.0) (62.0) (67.0) (69.5)

Applicable fuel -
(Cetane No.45 min.)

L 4.2
(engine only)
Overall
mm 719
length
mm 498
Overall
mm 717
height
kg
mm 130 130
10
1. General
(10) 4TNV98T
Revolving
Min-1 1500 1800 -
Continuous speed
rating kW 37.9 45.6
Output -
(hp) (51.5) (62.0)
Revolving
Min-1 1500 1800 2000 2200 2400 2500 2600
speed
Rated output
kW 41.9 50.4 50.7 55.5 60.3 62.5 64.0
Output
(hp) (57.0) (68.5) (69.0) (75.5) (82.0) (85.0) (87.0)
Max. no-load speed ( 25) min-1 1600 1895 2180 2400 2590 2700 2810

Applicable fuel -
(cetane No.45 min.)

L 4.2
(engine only)
Overall
mm 715
length
mm 575
Overall
mm 779
height
kg
Cooling fan (std.) mm 430 mm O/D, 8 blades suction type
mm 130 130
11
1. General
(11) 4TNV106
Revolving
Min-1 1500 1800 -
Continuous speed
rating kW 41.2 49.3
Output -
(hp) (56.0) (67.0)
Revolving
Min-1 1500 1800 2000 2200 2400 2500
speed
Rated output
kW 45.6 54.4 56.6 61.4 65.5 67.7
Output
(hp) (62.0 (74.0) (77.0) (83.5) (89.0) (92.0)

Applicable fuel -
(Cetane No.45 min.)

L 6.0
(engine only)
Overall
mm 808 776
length
mm 629 629
Overall
mm 803 803
height
kg
500 mm O/D, 500 mm O/D,
Cooling fan (std.) mm
7 blades pusher type 7 blades suction type
mm 150 150
12
1. General
(12) 4TNV106T
Revolving
Min-1 1500 1800 -
Continuous speed
rating kW 51.5 61.8
Output -
(hp) (70.0) (84.0)
Revolving
Min-1 1500 1800 2000 2200
speed
Rated output
kW 56.8 68.0 69.9 72.0
Output
(hp) (77.2 (92.5) (95.0) (97.9)
Max. no-load speed ( 25) min-1 1600 1895 2180 2400

Applicable fuel -
(Cetane No.45 min.)

L 6.0
(engine only)
Overall
mm 808 776
length
mm 629 628.6
Overall
mm 866 866
height
kg
500 mm O/D, 500 mm O/D,
Cooling fan (std.) mm
7 blades pusher type 7 blades suction type
mm 150 150
13
1. General
1.3 Fuel Oil, Lubricating Oil and Coolant Water
1.3.1 Fuel oil

IMPORTANT:
Only use the recommended fuel to obtain the best engine performance and prevent damage of parts,
also prevent air pollution.
(1) Selection of fuel oil

Use the following diesel fuels for best engine performance:
BS 2869 A1 or A2
Fuels equivalent to Japanese Industrial Standard, JIS. No. K2204-2
Fuel cetane number should be 45 or greater
(2) Fuel handling

Water and dust in the fuel oil can cause operation
failure. Use containers which are clean inside to
store fuel oil. Store the containers away from
rain water and dust.
Before supplying fuel, let the fuel container rest for
several hours so that water and dust in the fuel
are deposited on the bottom. Pump up only the
clean fuel.
(3) Fuel tank

Be sure to attach a drain cock, precipitation trap and
primary strainer to the fuel tank as shown illustration
right.
14
1. General
1.3.2 Lubricating oil

IMPORTANT:
Use of other than the specified engine oil may cause inner parts seizure or early wear, leading to
shorten the engine service life.
(1) Selection of engine lube oil

Use the following engine oil
API classification CD or CF
(Standards of America Petroleum Institute)
SAE viscosity 10W-30 or 15W-40
(Standard of Society of Automotive Engineering)
Engine oil with 10W30 or 15W40 can be used
throughout the year.
(Refer to the right figure.)
(2) Handling of engine oil

Carefully store and handle the oil so as to prevent
dust or dirt entrance. When supplying the oil,
pay attention and clean around the filler port.
Do not mix different types of oil as it may
adversely affect the lubricating performance.
When touching engine oil by hand, the skin of the hand may become
rough. Be careful not to touch oil with your hands without protective
gloves. If touch, wash your hands with soap and water thoroughly.
1.3.3 Coolant water

Use clean soft water and be sure to add the Long Life Coolant Antifreeze (LLC) in order to prevent rust
built up and freezing. If there is any doubt over the water guality, distilled water or pre-mixed coolant
should be used.
The coolants / antifreezes, which are good performance for example, are shown below.
TEXACO LONG LIFE COOLANT ANTIFREEZE, both standard and pre-mixed.
Product codes 7997 and 7998
HAVOLINE EXTENDED LIFE ANTIFREEZE / COOLANT
Product code 7994
IMPORTANT:
Be sure to add Long Life Coolant Antifreeze(LLC) to soft water. In cold season, the LLC is
especially important. Without LLC, cooling performance will decrease due to scale and rust in the
coolant water line. Without LLC, coolant water will freeze and expand to break the cooling line.
Be sure to use the mixing ratios specified by the LLC manufacturer for your temperature range.
Do not mix different types (brand) of LLC, chemical reactions may make the LLC useless and
engine trouble could result.
Replace the coolant water every once a year.
When handling Long Life Coolant Antifreeze, wear protective rubber

gloves not to touch it. If LLC gets eyes or skin, wash with clean water
at once.
15
1. General
1.4 Engine External Views
16

TNV Series Diesel Engine WEBMTNV000 SAMPLE Komatsu

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WEBMTNV000

APPLICABLE ENGINE MODEL

DANGER-indicates an imminently hazardous situation, which,

WARNING-indicates a potentially hazardous situation, which, if not

CAUTION-indicates a potentially hazardous situation, which, if not

(1) SERVICE AREA

Safe / Adequate Work Area

Bright, Safely Illuminated Area

Safe Work Clothing

Appropriate Lifting / Holding

(4) GENUINE PARTS and MATERIALS

(7) WASTE MANAGEMENT

Preventing burns from scalding

(2) Preparation for Service Work

(3) Preparation before Disassembly

(4) Precautions in Disassembly

(5) Precautions for Inspection and Measurement

(6) Precautions for Reassembly

(7) Precautions for Adjustment and Check

How to Read this Manual

(3) Definition of Terms

Abbreviation Meaning Abbreviation Meaning

Sub-Assy 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 Min-1 revolutions per minute

IN Intake PS Output (metric horsepower)

EX Exhaust T Bolt/nut tightening torque

2. Inspection and Adjustment........................................................................ 22

7. FUEL INJECTION PUMP/GOVERNOR...................................................114

8. TURBOCHAGER: Disassembly, inspection and reassembly.....................118

9. STARTING MOTOR ................................................................................ 140

11. ELECTRIC WIRING .............................................................................. 180

12. SERVICE STANDARDS ....................................................................... 185

13. TIGHTENING TORQUE for BOLTS and NUTS .................................... 196

1.1 Engine Nomenclature

The engine specification class

VM Variable load Variable speed 2000-3000

Engine specification class - CL VM

Type - Vertical, in-line, 4-cycle, water-cooled diesel engine

Combustion chamber - Direct injection

Cylinder bore stroke mm mm 82 84

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

Lubricant capacity Total L 3.6 5.5

Fun V pulley diameter (std.) mm 120 90 110 110

Engine specification class - CL VM

Type - Vertical, in-line, 4-cycle, water-cooled diesel engine

Combustion chamber - Direct injection

Cylinder bore stroke mm mm 84 90

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