KOMATSU 70E,76E-5 SERIES DIESEL ENGINE SERVICE REPAIR MANUAL (SEBM037701) – PDF DOWNLOAD

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KOMATSU 70E,76E-5 SERIES DIESEL ENGINE SERVICE REPAIR MANUAL (SEBM037701)

KOMATSU 70E,76E-5 SERIES DIESEL ENGINE SERVICE REPAIR MANUAL (SEBM037701) – PDF DOWNLOAD:

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KOMATSU 70E,76E-5 SERIES DIESEL ENGINE SERVICE REPAIR MANUAL (SEBM037701)

This manual describes the service procedures for the 70E, 76E-5 series engines. 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.

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.

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 76E-5 series engines. 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 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.

TABLE OF CONTENTS:

KOMATSU 70E,76E-5 SERIES DIESEL ENGINE SERVICE REPAIR MANUAL (SEBM037701)

COVER.............................................................................  1
CONTENTS.......................................................................... 15
1. GENERAL........................................................................ 16
	1.1 SPECIFICATIONS............................................................ 17
	1.2 ENGINE EXTERNAL VIEWS..................................................... 19
	1.3 STRUCTURAL DESCRIPTION.................................................... 20
2. INSPECTION AND ADJUSTMENT...................................................... 21
	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.............................. 43
	2.3 ADJUSTING THE NO-LOAD MAXIMUM OR MINIMUM SPEED............................ 45
	2.4 SENSOR INSPECTION......................................................... 46
		2.4.1 OIL PRESSURE SWITCH................................................. 46
		2.4.2 THERMO SWITCH....................................................... 46
	2.5 WATER LEAK CHECK IN COOLING WATER SYSTEM.................................. 46
	2.6 RADIATOR CAP INSPECTION................................................... 47
	2.7 THERMOSTAT INSPECTION .................................................... 47
	2.8 ADJUSTING OPERATION ...................................................... 48
	2.9 LONG STORAGE.............................................................. 48
3. TROUBLESHOOTING................................................................ 49
	3.1 PREPARATION BEFORE TROUBLESHOOTING........................................ 50
	3.2 QUICK REFERENCE TABLE FOR TROUBLESHOOTING    ............................. 51
	3.3 TROUBLESHOOTING BY MEASURING COMPRESSION PRESSURE......................... 54
4. DISASSEMBLY, INSPECTION AND REASSEMBLY OF ENGINES.............................. 56
	4.1 COMPLETE DISASSEMBLY AND REASSEMBLY....................................... 57
		4.1.1 INTRODUCTION........................................................ 57
		4.1.2 SPECIAL SERVICE TOOLS............................................... 58
		4.1.3 COMPLETE DISASSEMBLY................................................ 63
		4.1.4 PRECAUTIONS BEFORE AND DURING REASSEMBLY............................ 67
		4.1.5 ADJUSTING OPERATION ................................................ 67
	4.2 CYLINDER HEAD: DISASSEMBLY, INSPECTION AND REASSEMBLY..................... 68
		4.2.1 COMPONENTS (2-VALVE CYLINDER HEAD).................................. 68
		4.2.2 DISASSEMBLY PROCEDURE............................................... 69
		4.2.3 REASSEMBLY PROCEDURE................................................ 69
		4.2.4 SERVICING POINTS.................................................... 70
		4.2.5 PARTS INSPECTION AND MEASUREMENT.................................... 74
		4.2.6 VALVE SEAT CORRECTION .............................................. 78
		4.2.7 VALVE GUIDE REPLACEMENT ............................................ 79
		4.2.8 VALVE STEM SEAL REPLACEMENT......................................... 80
	4.3 GEAR TRAIN AND CAMSHAFT................................................... 81
		4.3.1 COMPONENTS.......................................................... 81
		4.3.2 DISASSEMBLY PROCEDURE............................................... 81
		4.3.3 REASSEMBLY PROCEDURE................................................ 82
		4.3.4 SERVICING POINTS.................................................... 82
		4.3.5 PARTS INSPECTION AND MEASUREMENT ................................... 85
		4.3.6 OIL SEAL REPLACEMENT (GEAR CASE SIDE)............................... 86
		4.3.7 CAMSHAFT BUSHING REPLACEMENT ....................................... 86
	4.4 CYLINDER BLOCK............................................................ 87
		4.4.1 COMPONENTS.......................................................... 87
		4.4.2 DISASSEMBLY PROCEDURE............................................... 88
		4.4.3 REASSEMBLY PROCEDURE................................................ 88
		4.4.4 SERVICING POINTS.................................................... 88
		4.4.5 PARTS INSPECTION AND MEASUREMENT.................................... 92
		4.4.6 CYLINDER BORE CORRECTION............................................101
		4.4.7 PISTON PIN METAL REPLACEMENT .......................................102
		4.4.8 OIL SEAL REPLACEMENT (FLYWHEEL HOUSING SIDE)........................102
5. LUBRICATION SYSTEM ............................................................103
	5.1 LUBRICATION SYSTEM DIAGRAM................................................104
	5.2 TROCHOID PUMP COMPONENTS..................................................105
	5.3 DISASSEMBLY (REVERSE THE PROCEDURE BELOW FOR ASSEMBLY)....................105
	5.4 SERVICING POINTS..........................................................105
	5.5 PARTS INSPECTION AND MEASUREMENT .........................................106
6. COOLING SYSTEM ................................................................107
	6.1 COOLING WATER SYSTEM .....................................................108
	6.2 COOLING WATER PUMP COMPONENTS.............................................108
	6.3 DISASSEMBLY (REVERSE THE PROCEDURE BELOW FOR ASSEMBLY)....................109
	6.4 SERVICING POINTS..........................................................109
7. FUEL INJECTION PUMP/GOVERNOR...................................................110
	7.1 INTRODUCTION .............................................................111
	7.2 FUEL INJECTION PUMP  .....................................................111
		7.2.1 FUEL SYSTEM DIAGRAM.................................................111
		7.2.2 EXTERNAL VIEW AND COMPONENTS........................................112
		7.2.3 DISASSEMBLY PROCEDURE...............................................113
		7.2.4 ASSEMBLY PROCEDURE..................................................113
		7.2.5 CONFIRMATION AND ADJUSTMENT OF FUEL INJECTION TIMING................113
		7.2.6 CONFIRMATION AND ADJUSTMENT OF NO-LOAD MAXIMUM AND MINIMUM SPEED....113
8. THE SPECIFICATIONS OF A STARTING MOTOR AND THE CHARACTERISTICS.................114
	8.1 THE SPECIFICATIONS AND THE CHARACTERISTICS................................115
		8.1.1 SPECIFICATIONS......................................................115
		8.1.2 CHARACTERISTICS.....................................................115
	8.2 THE STRUCTURE OF A STARTING MOTOR AND THE WIRING DIAGRAM..................116
		8.2.1 STRUCTURE...........................................................116
		8.2.2 WIRING DIAGRAM OF A STARTING MOTOR..................................117
	8.3 PERFORMANCE...............................................................117
9. ALTERNATOR.....................................................................118
	9.1 20A ALTERNATOR............................................................119
		9.1.1 SPECIFICATIONS......................................................119
		9.1.2 STRUCTURE...........................................................120
		9.1.3 WIRING DIAGRAM......................................................121
		9.1.4 STANDARD OUTPUT CHARACTERISTICS.....................................121
		9.1.5 INSPECTION..........................................................122
	9.2 40A ALTERNATOR ...........................................................123
		9.2.1 COMPONENTS..........................................................123
		9.2.2 SPECIFICATIONS......................................................124
		9.2.3 WIRING DIAGRAM......................................................124
		9.2.4 STANDARD OUTPUT CHARACTERISTICS ....................................125
		9.2.5 INSPECTION..........................................................125
		9.2.6 TROUBLESHOOTING ....................................................126
10.ELECTRIC WIRING ...............................................................127
	10.1 ELECTRIC WIRING DIAGRAM..................................................128
	10.2 PRECAUTION ON ELECTRIC WIRING............................................130
		10.2.1 ALTERNATOR.........................................................130
		10.2.2 STARTING MOTOR.....................................................131
		10.2.3 CURRENT LIMITER....................................................132
		10.2.4 SECTION AREA AND RESISTANCE OF ELECTRIC WIRE.......................133
11.SERVICE STANDARDS..............................................................134
	11.1 ENGINE TUNING............................................................135
	11.2 ENGINE BODY..............................................................136
		11.2.1 CYLINDER HEAD......................................................136
		11.2.2 GEAR TRAIN AND CAMSHAFT............................................137
		11.2.3 CYLINDER BLOCK ....................................................138
	11.3 LUBRICATING OIL SYSTEM (TROCHOID PUMP)...................................141
12.TIGHTENING TORQUE FOR BOLTS AND NUTS...........................................142
	12.1 TIGHTENING TORQUES FOR MAIN BOLTS AND NUTS...............................143
	12.2 TIGHTENING TORQUES FOR STANDARD BOLTS AND NUTS...........................144

PLEASE NOTE:

⦁ This is the SAME exact manual used by your dealers to fix your vehicle.
⦁ The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
⦁ Any queries / doubts regarding your purchase, please feel free to contact [email protected]