Komatsu 3D95E -1 Series Engine Shop Manual SEN06834-02 – PDF DOWNLOAD

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Komatsu 3D95E -1 Series Engine Shop Manual SEN06834-02 – PDF DOWNLOAD

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Komatsu 3D95E -1 Series Engine Shop Manual SEN06834-02 – PDF DOWNLOAD

FOREWORD, SAFETY, BASIC INFORMATION:
HOW TO READ THE ENGINE SHOP MANUAL:
• Some of the attachments and options described in this shop manual may not be available in some areas. If
they are required, consult your Komatsu distributor.
• The materials and specifications are subject to change without notice.
• Shop manuals are available for “machine part” and “engine part”. For the engine unit, see the shop manual
for the machine which has the same engine model.
• Actual machine may differ from the images which are contained in this manual. A typical model is shown in
the illustrations of this shop manual.
Composition of the shop manual:
This shop manual contains technical information necessary to perform services in workshops. It is divided into
the following chapters for the ease of use.
00 INDEX AND FOREWORD:
This section describes the index, foreword, safety, and basic information.
01 SPECIFICATIONS
This section describes the specifications of the machine.
10 STRUCTURE AND FUNCTION
This section describes the structure and operation of each component with respect to each system. “STRUCTURE
AND FUNCTION” is helpful in not only understanding the structure of each component but performing
troubleshooting.
20 STANDARD VALUE TABLE
This section describes the standard values for new machine and failure criteria for testing and adjusting, and
troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge
troubles in troubleshooting.
50 DISASSEMBLY AND ASSEMBLY
This section describes the special tools, work procedures, and safety precautions necessary for removal, installation,
disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and
weight of the coating materials, lubricants, and coolant necessary to these works are shown.
60 MAINTENANCE STANDARD
This section describes the maintenance standard value of each component. The maintenance standard shows
the criteria and remedies for disassembly and assembly.

TABLE OF CONTENTS:

Komatsu 3D95E -1 Series Engine Shop Manual SEN06834-02 – PDF DOWNLOAD

COVER 1
00 INDEX AND FOREWORD 3
INDEX 4
FOREWORD, SAFETY, BASIC INFORMATION 6
HOW TO READ THE ENGINE SHOP MANUAL 6
SAFETY NOTICE FOR OPERATION 8
PRECAUTIONS TO PREVENT FIRE 16
ACTIONS IF FIRE OCCURS 18
PRECAUTIONS WHEN YOU DISPOSE OF WASTE MATERIALS 19
ENGINE TECHNOLOGY TO CONFORM EXHAUST GAS EMISSION 20
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 21
PRECAUTIONS WHEN YOU DISCONNECT AND CONNECT PIPINGS 24
PRECAUTIONS WHEN YOU HANDLE ELECTRICAL EQUIPMENT 31
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 33
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 34
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 35
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER 35
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER 36
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER 37
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 39
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR 43
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR 44
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL 46
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH 47
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 49
STANDARD TIGHTENING TORQUE TABLE 50
CONVERSION TABLE 57
ABBREVIATION LIST 62
01 SPECIFICATION 65
CONTENTS 66
SPECIFICATIONS 67
OUTLINE OF EXHAUST GAS REGULATION 67
SYSTEM DIAGRAM OF ENGINE CONFORMED TO TIER4 REGULATION 68
LIST OF APPLICABLE MACHINES: 3D95E-1 70
SPECIFICATIONS 71
SPECIFICATIONS: SAA3D95E-1(PC78US-11, PC78US-11E0, PC88MR-11, PC88MR-11E0) 71
ENGINE GENERAL VIEW 72
ENGINE GENERAL VIEW: SAA3D95E-1(PC78US-11, PC78US-11E0, PC88MR-11, PC88MR-11E0) 72
WEIGHT TABLE 80
WEIGHT TABLE: 3D95E-1 80
ENGINE PERFORMANCE CURVE 81
ENGINE PERFORMANCE CURVE: SAA3D95E-1 (PC78US-11, PC78US-11E0, PC88MR-11, PC88MR-11E0) 81
10 STRUCTURE AND FUNCTION 83
CONTENTS 84
ENGINE SYSTEM 86
LAYOUT OF ENGINE COMPONENTS 86
LAYOUT DRAWING OF ENGINE COMPONENTS 86
INTAKE AND EXHAUST SYSTEM PARTS 89
LAYOUT DRAWING OF INTAKE AND EXHAUST SYSTEM 89
INTAKE AND EXHAUST SYSTEM CIRCUIT DIAGRAM 90
FUNCTION OF INTAKE AND EXHAUST SYSTEM 90
AIR CLEANER 92
INTAKE AIR HEATER 94
ENGINE MAIN BODY PARTS 95
CYLINDER HEAD 95
CYLINDER BLOCK 98
MAIN DRIVE PARTS 100
TIMING GEAR 103
FRONT COVER 104
VALVE SYSTEM 105
FLYWHEEL AND FLYWHEEL HOUSING 107
TURBOCHARGER SYSTEM 108
TURBOCHARGER 108
EGR SYSTEM 111
EGR VALVE 114
EGR COOLER 116
HIGH EFFICIENCY BREATHER SYSTEM 117
HIGH EFFICIENCY BREATHER 118
EXHAUST THROTTLE VALVE 120
KDOC 121
KDPF 123
LUBRICATION SYSTEM 127
LAYOUT DRAWING OF LUBRICATION SYSTEM PARTS 127
LUBRICATION SYSTEM CIRCUIT DIAGRAM 128
ENGINE OIL PUMP 129
ENGINE OIL FILTER 131
ENGINE OIL COOLER 132
ENGINE OIL PAN 133
FUEL SYSTEM 134
LAYOUT DRAWING OF FUEL SYSTEM PARTS 134
FUEL SYSTEM CIRCUIT DIAGRAM 135
CRI SYSTEM 136
SUPPLY PUMP 140
COMMON RAIL 141
INJECTOR 143
FUEL PREFILTER 148
FUEL MAIN FILTER 149
COOLING SYSTEM 150
LAYOUT DRAWING OF COOLING SYSTEM PARTS 150
COOLING SYSTEM CIRCUIT DIAGRAM 151
DRIVE PULLEY 152
WATER PUMP 153
THERMOSTAT 154
ELECTRICAL SYSTEM 158
COMPONENT PARTS OF ELECTRICAL SYSTEM 158
ALTERNATOR 158
STARTING MOTOR 161
ENGINE WIRING HARNESS 163
ENGINE CONTROLLER 165
SENSOR 172
LAYOUT DRAWING OF ENGINE SENSOR 172
STRUCTURE OF AMBIENT PRESSURE SENSOR 174
FUNCTION OF AMBIENT PRESSURE SENSOR 174
STRUCTURE OF ENGINE OIL PRESSURE SWITCH 175
FUNCTION OF ENGINE OIL PRESSURE SWITCH 175
STRUCTURE OF CHARGE (BOOST) PRESSURE AND TEMPERATURE SENSOR 176
FUNCTION OF CHARGE (BOOST) PRESSURE AND TEMPERATURE SENSOR 176
STRUCTURE OF COOLANT TEMPERATURE SENSOR 177
FUNCTION OF COOLANT TEMPERATURE SENSOR 177
STRUCTURE OF NE (CRANKSHAFT) SPEED SENSOR 178
FUNCTION OF NE (CRANKSHAFT) SPEED SENSOR 178
STRUCTURE OF Bkup (CAM) SPEED SENSOR 179
FUNCTION OF Bkup (CAM) SPEED SENSOR 179
STRUCTURE OF COMMON RAIL PRESSURE SENSOR 180
FUNCTION OF COMMON RAIL PRESSURE SENSOR 180
STRUCTURE OF MASS AIR FLOW AND TEMPERATURE SENSOR 181
FUNCTION OF MASS AIR FLOW AND TEMPERATURE SENSOR 181
STRUCTURE OF AIR CLEANER CLOGGING SENSOR 182
FUNCTION OF AIR CLEANER CLOGGING SENSOR 182
STRUCTURE OF EGR VALVE (WITH BUILT-IN POSITION SENSOR) 183
FUNCTION OF EGR VALVE (WITH BUILT-IN POSITION SENSOR) 183
STRUCTURE OF EXHAUST THROTTLE VALVE (WITH BUILT-IN POSITION SENSOR) 184
FUNCTION OF EXHAUST THROTTLE VALVE (WITH BUILT-IN POSITION SENSOR) 184
20 STANDARD VALUE TABLE 185
CONTENTS 186
STANDARD VALUE TABLE FOR ENGINE 187
STANDARD VALUE TABLE FOR ENGINE: SAA3D95E-1 (PC78US-11, PC78US-11E0, PC88MR-11, PC88MR-11E0) 187
PERFORMANCE TEST STANDARD AND STANDARD FOR OPERATION OF ENGINE FOR BREAK IN PERIOD 189
PERFORMANCE TEST STANDARD AND STANDARD FOR OPERATION OF ENGINE FOR BREAK IN PERIOD: SAA3D95E-1 (PC78US-11, PC78US-11E0, PC88MR-11, PC88MR-11E0) 189
50 DISASSEMBLY AND ASSEMBLY 191
CONTENTS 192
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY 193
HOW TO READ THIS MANUAL 193
COATING MATERIALS LIST 195
SPECIAL TOOLS LIST 199
SKETCHES OF SPECIAL TOOLS 201
ENGINE RELATED 202
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY 202
DISASSEMBLE ENGINE GENERALLY 206
ASSEMBLE ENGINE GENERALLY 254
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY 332
REMOVE SUPPLY PUMP ASSEMBLY 333
INSTALL SUPPLY PUMP ASSEMBLY 340
REMOVE AND INSTALL ENGINE FRONT OIL SEAL 349
REMOVE ENGINE FRONT OIL SEAL 349
INSTALL ENGINE FRONT OIL SEAL 351
60 MAINTENANCE STANDARD 355
CONTENTS 356
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 357
ENGINE SYSTEM 359
INTAKE AND EXHAUST SYSTEM PARTS 359
MAINTENANCE STANDARD OF TURBOCHARGER 359
ENGINE MAIN BODY PARTS 360
MAINTENANCE STANDARD OF CYLINDER HEAD 360
MAINTENANCE STANDARD OF CYLINDER BLOCK 362
MAINTENANCE STANDARD OF CRANKSHAFT 365
MAINTENANCE STANDARD OF PISTON 367
MAINTENANCE STANDARD OF CONNECTING ROD 369
MAINTENANCE STANDARD OF TIMING GEAR 371
MAINTENANCE STANDARD OF CAMSHAFT 372
MAINTENANCE STANDARD OF VALVE AND VALVE GUIDE 374
MAINTENANCE STANDARD OF ROCKER ARM 376
MAINTENANCE STANDARD OF TAPPET 378
MAINTENANCE STANDARD OF FLYWHEEL 379
LUBRICATION SYSTEM 381
MAINTENANCE STANDARD OF ENGINE OIL PUMP 381
INDEX 383

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