KOMATSU 3D95E -1 SERIES SHOP MANUAL SEN06834-04 – PDF DOWNLOAD

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KOMATSU 3D95E -1 SERIES SHOP MANUAL SEN06834-04 – PDF DOWNLOAD

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KOMATSU 3D95E -1 SERIES SHOP MANUAL SEN06834-04 – PDF DOWNLOAD

Language : English
Pages : 386
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

KOMATSU 3D95E -1 SERIES SHOP MANUAL SEN06834-04 – 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
		 Procedures If Fire Occurs..................................................................................................................................... 18
		 Precautions When You Discard Waste Materials.................................................................................................................. 19
		 Engine Technology to Conform Exhaust Gas Emission............................................................................................................. 20
		 Precautions When You Handle Hydraulic Equipment............................................................................................................... 21
		 Precautions When You Disconnect and Connect Pipings........................................................................................................... 24
		 Precautions When You Handle Electrical Equipment.............................................................................................................. 31
		 Precautions When You Handle Fuel System Equipment............................................................................................................. 33
		 Precautions When You Handle Intake System Equipment........................................................................................................... 34
		 Disconnect and Connect Push-Pull Type Coupler................................................................................................................. 35
			 How to Disconnect and Connect Type 1 Push-Pull Type Coupler............................................................................................... 35
			 How to Disconnect and Connect Type 2 Push-Pull Type Coupler............................................................................................... 36
			 How to Disconnect and Connect Type 3 Push-Pull Type Coupler............................................................................................... 37
		 Precautions for Disconnection and Connection of Connectors.................................................................................................... 39
		 Disconnect and Connect Deutsch Connector...................................................................................................................... 43
		 How to Disconnect and Connect Slide Lock Type Connector....................................................................................................... 44
		 Disconnect and Connect Connector with Lock to Pull............................................................................................................ 46
		 Disconnect and Connect Connector with Lock to Push............................................................................................................ 47
		 Disconnect and Connect Connector with Housing to Rotate....................................................................................................... 49
		 Standard Tightening Torque Table.............................................................................................................................. 50
		 Conversion Table.............................................................................................................................................. 57
		 Abbreviation List............................................................................................................................................. 62
 01 Specification...................................................................................................................................................... 65
	 Table of 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, PC78UU-11, PC88MR-11, PC88MR-11E0).................................................................... 71
		 Engine General View........................................................................................................................................... 72
			 Engine General View: SAA3D95E-1 (PC78US-11, PC78US-11E0, PC78UU-11, 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, PC78UU-11, PC88MR-11, PC88MR-11E0).......................................................... 81
 10 Structure and Function............................................................................................................................................. 83
	 Table of 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 (Camshaft) Speed Sensor.................................................................................................................179
			 Function of Bkup (Camshaft) 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
	 Table of Contents.................................................................................................................................................186
	 Standard Value Table for Engine...................................................................................................................................187
		 Standard Value Table for Engine: SAA3D95E-1 (PC78US-11, PC78US-11E0, PC78UU-11, PC88MR-11, PC88MR-11E0).......................................................187
	 Running-in Standard and Performance Test Standard.................................................................................................................189
		 Performance Test Standard and Standard for Operation of Engine for Break in Period: SAA3D95E-1 (PC78US-11, PC78US-11E0, PC78UU-11, PC88MR-11, PC88MR-11E0)....189
 50 Disassembly and Assembly...........................................................................................................................................191
	 Table of Contents.................................................................................................................................................192
	 Precautions Before Work...........................................................................................................................................193
	 Related Information on Disassembly and Assembly...................................................................................................................194
		 How to Read This Manual.......................................................................................................................................194
		 Coating Materials List........................................................................................................................................195
		 Special Tool List.............................................................................................................................................200
		 Sketches of Special Tools.....................................................................................................................................202
	 Engine System.....................................................................................................................................................203
		 Disassemble and Assemble Engine Generally.....................................................................................................................203
			 Disassemble Engine Generally..............................................................................................................................207
			 How to Assemble Engine Generally..........................................................................................................................255
		 Remove and Install Supply Pump Assembly.......................................................................................................................333
			 How to Remove Supply Pump Assembly........................................................................................................................334
			 How to Install Supply Pump Assembly.......................................................................................................................341
		 Remove and Install Engine Front Oil Seal......................................................................................................................350
			 How to Remove Engine Front Oil Seal.......................................................................................................................350
			 How to Install Engine Front Oil Seal......................................................................................................................352
 60 Maintenance Standard...............................................................................................................................................355
	 Table of Contents.................................................................................................................................................356
	 Explanation of Terms for Maintenance Standard.....................................................................................................................357
	 Engine System.....................................................................................................................................................359
		 Intake and Exhaust System Parts...............................................................................................................................359
			 Maintenance Standard for Turbocharger.....................................................................................................................359
		 Engine Main Body Parts........................................................................................................................................360
			 Maintenance Standard for Cylinder Head....................................................................................................................360
			 Maintenance Standard for Cylinder Block...................................................................................................................362
			 Maintenance Standard for Crankshaft.......................................................................................................................365
			 Maintenance Standard for Piston...........................................................................................................................367
			 Maintenance Standard for Connecting Rod...................................................................................................................369
			 Maintenance Standard for Timing Gear......................................................................................................................371
			 Maintenance Standard for Camshaft.........................................................................................................................372
			 Maintenance Standard for Valve and Valve Guide............................................................................................................374
			 Maintenance Standard for Rocker Arm.......................................................................................................................376
			 Maintenance Standard for Tappet...........................................................................................................................378
			 Maintenance Standard for Flywheel.........................................................................................................................379
		 Lubrication System............................................................................................................................................381
			 Maintenance Standard for Engine Oil Pump..................................................................................................................381
Index..................................................................................................................................................................383

DESCRIPTION:

KOMATSU 3D95E -1 SERIES SHOP MANUAL SEN06834-04 – PDF DOWNLOAD

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.

S.S 17/12/24