KOMATSU D900-SERIES ENGINE WORKSHOP MANUAL 2974770M1 – PDF DOWNLOAD

ENGINE, general
Description
Engine D 943 3, Injection pump side
D 943 B, Camshofr side
D 962 B, Inicciion pump side
D 962 B, Camshaft side
D 962 K, Inieclion pump side
D 962 K, Camshafl side
D 963 B, lniacrion pump side
D 963 B, Cmuhaft side
D 963 K, Inlectian pump side
D 963 K, Camshafl side
D 963 A i, lnieclion pwnp sidc
D 963 A I, Canshafi side
D 963 A 2, Injection’pump side
D 963 A 2, Camshaft ride
Fault finding char!
Engine speed, testing and adiusring
Engine mountings, replacing, D 962 K Dozer
Engine mounfings, replacing, D 963 B, D 963 A I, D 963 A 2
General technical data, repair values D 943 8
D 962 3
Page 5000 – 500 shows from D 962 K
which engine number imporf- 9 963 3
an! amendments have tdien D 963 K
place to the repair value.
D 963 A i
D 963 A 2
Czlinder block
Cylinder limrs, removing
Cylinder liners, refining
Rear crarkshaf? oil seal, replacing
Side covers and gaskets, replacing
Czlinder head, comelete
4 Compression pressure test

Adjusting valve clearances
Air intake pipes and hoses, removing and refitting D 963 A i, D 963 A 2
Exhaust silencer, supports and gaskets, removing and
refittingD9628/ D962 K/D963 B/D963 K
Air intake manifolds and hoses, removing and refitting
Cylinder head water pipes, removing and refitting
D943 B/D962B/D962K/D963K
Heat exchanger water pipes, replacing D 943 B/D 962 8/0 962 K/D 963 K
Cylinder head water pipes and hoses replacing
D9638/D963Ai/D963A2 –
Cob heater shut-off valve, removing, refitting and replacing .
Rocker arms, rocker shafts and push rods, removing
Rocker arms, rocker shafts and push rods, refitting
Cylinder hood complete, removing and refitting
Cylinder head, dignantling
Valve seat iruerts, refitting

# Valve scat inserts, machining (in situ)

¥ Valves and seats, regriruding

v Valve guides, refitting
Cylinder head, assembling –
Pistons / connecting rods, complete
Pistons/ connecting rods, removing
Fitting piston to connecting rod
Pistons/connecting rods, refitting
Crarkshat’t, complete
Crankshaft, removing
Crankshaft, refitting

l Please note the repair value amendment: on page 5WD – 500
EEine timing gear
Front crankshaft oil seal, replacing
Push rods, tappets cnd camshaft, removing I
Fuel inicction pump drive, removing
Fuel iniection pump drive, dismantling and assembling
Fuel inlection pump drive, dismantling and assembling D 963 A 2
Camshaft bearings, replacing
Toppers, push rods and camshaft refitting
inicction pump drive, refitting I
Timing gear, setting
Timing case cover, sump, pulle and push rods, refitting
Chedcing the backlash and end float
Engine lubrication fitem
Oil circuit diagram D 943 B

D 962 B / D 962 K

D 963 K

D 963 8

o 963 A 1 / D 953 A 2
Oil pump, pressure relief valve and piston cooling
nozzle, removing
Oil pump dismantling
Oil pump assembling
Oil pump dismantled
Oil pump, pressure relief valve and piston cooling
nozzle, refitting
Oil filter complete and filter support removing and
refittingD9638/D963K/D963A i/D963A2
Oil iilter hose and support, dismantled
D963 B/D963K,’D963Ai/D963A2
Oil filter complete, removing and refitting
D9433/D962 B/”D962K
Oil pipes and connections, repairing and replacing
Turbo supercharger oil Feed pipes, removing and refitting
Oil sump and gasket, removing and refitting
Fuel injection 525mm
Circulr diagrams of the Fuel inieclion and cold-start systems
Changes to the 5J0] inicction system
Function of rho cold-start device installed in the Fuel injection pump
Checking the commencement of injection
Selling the commencement of injection
Engine control, injection D 962 K
Accelerator cable, to adjustment D 943 8/ D 962 8/
D9633/D963Al/D963A2
Fuel injection pump, removing
Fuel injection pump, refining
Fuel injectors removing and refining
Fuel injectors, feeling and repairing
injection pipes and fuel leak-off hoses, replacing
Glow plug, removing and refitting D 963 A l / D 963 A 2
Fuel Feed pump, “:3?an and replacing
Hand priming pump, Reeling and replacing
Engine accessory equipment
Cooling fun, removing and refilling D 9&3 A l / D 963 A 2
Fan pulley, removing and refitting D 963 A l/ D 963 A 2
Fan spindle bearing, removing and refining D 963 A l / D 963 A 2
Fan pulley, replacing D 962 K
Fan spindle bear-Era, removing and refining D 962 K
Fan spindle bearing, dismantling and assembling D 962 K
Water pump pulley, replacing D 962 K
Water pump pulley, removing and refining
D9638/D963Al/ D963A2
V-belt tensioner, removing, refining and reconditioning
D963K/D9638/D963A1/D963A2
Water pump, removing and refining D943 3/ D 962 K
Water pump, removing and refining D963 8 / D 963 A ‘l / D 963 A 2
Water pump, dismantling and assembling D 943 B / D 962 K
Please note the repair value amendment on page 5000 – 500
Thermostat removing and refitting
D9433/D9628/D962K/D963K

Thermostats, removing and refitting
D9QB/D963Al/D963A2

Hints for the operation of turbo supercharged diesel engines
Turbo supercharger removing and refitting D 963 Ai / D 963 A 2
Turbo supercharger, sectional view

Turbo supercharger, dismantling

Turbo supercharger, assembling

Air compressor, removing and refitting
D9438/D962B/D9638/D963At/D963A2

Air compressor pulley, removing and refitting
D9438/D9628/D963 B/D963Ai/D963A2
Flywheel / ring gear, removing, refitting and replacing
Starter motor, removing and refitting

Alternator, removing and refitting

Alternator pulley, removing and refitting

Special tools