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

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

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

Language : English
Pages : 386
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File Type : PDF
Size: 20.2 MB

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

The Komatsu 3D95E-1 Series Diesel Engine Shop Manual SEN06834-02 is a comprehensive guide that provides detailed information on the construction, operation, and maintenance of the 3D95E-1 series diesel engine. The manual is designed to help mechanics and technicians with repair and maintenance procedures and is an essential resource for anyone responsible for the upkeep of these engines.

• The manual begins with an introduction to the 3D95E-1 series diesel engine, which provides information on the engine’s specifications, performance characteristics, and construction features. The manual also outlines the engine’s maintenance schedule and recommended service intervals.
• The manual then provides detailed instructions on the disassembly, inspection, repair, and reassembly of various engine components. The manual covers topics such as the cylinder block, cylinder head, crankshaft, pistons, connecting rods, camshaft, and timing gears.
• The cylinder block section provides detailed instructions on the removal and installation of the cylinder block, as well as instructions for inspection, repair, and reassembly of various cylinder block components, such as the cylinder liners and main bearings. The cylinder head section covers the inspection, repair, and replacement of various cylinder head components, such as valves, springs, and guides. The crankshaft section provides instructions on the inspection, repair, and replacement of various crankshaft components, such as the main and connecting rod bearings. The piston section covers the inspection, repair, and replacement of various piston components, such as rings and wrist pins. The connecting rod section provides instructions on the inspection, repair, and replacement of various connecting rod components, such as bearings and bolts. The camshaft and timing gears section covers the inspection, repair, and replacement of various camshaft and timing gear components, such as bearings, gears, and chains.
• The manual also includes sections on the fuel injection system, lubrication system, and cooling system. These sections provide detailed instructions on the repair and maintenance of these critical engine systems. The fuel injection section covers topics such as the injection pump, fuel injectors, and fuel lines. The lubrication system section covers topics such as the oil pump, oil filter, and oil cooler. The cooling system section covers topics such as the radiator, water pump, and thermostat.
• In addition to these repair and maintenance procedures, the manual includes a section on troubleshooting. This section provides detailed instructions on how to diagnose and fix common problems that may occur during the operation of the engine. This section includes a list of common symptoms, possible causes, and recommended solutions for each problem.
• Overall, the Komatsu 3D95E-1 Series Diesel Engine Shop Manual SEN06834-02 is an essential resource for mechanics and technicians who are responsible for the repair and maintenance of the 3D95E-1 series diesel engine. It provides detailed information on how to disassemble, inspect, repair, and reassemble the engine’s various components, as well as important safety information to help prevent accidents and injuries. The manual is a must-have for anyone who needs to perform repairs or maintenance on these engines.

TABLE OF CONTENTS:

Komatsu 3D95E-1 Series Diesel 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