Komatsu 3D95E-1 Series Engine Shop Manual SEN06834-02

Description

• Model List:
  • 3D95E-1 Series Engine

• 1. COVER
• 2. INDEX AND FOREWORD
• 2.1. INDEX
• 2.2. FOREWORD, SAFETY, BASIC INFORMATION
• 2.2.1. HOW TO READ THE ENGINE SHOP MANUAL
• 2.2.2. SAFETY NOTICE FOR OPERATION
• 2.2.3. PRECAUTIONS TO PREVENT FIRE
• 2.2.4. ACTIONS IF FIRE OCCURS
• 2.2.5. PRECAUTIONS WHEN YOU DISPOSE OF WASTE MATERIALS
• 2.2.6. ENGINE TECHNOLOGY TO CONFORM EXHAUST GAS EMISSION
• 2.2.7. PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT
• 2.2.8. PRECAUTIONS WHEN YOU DISCONNECT AND CONNECT PIPINGS
• 2.2.9. PRECAUTIONS WHEN YOU HANDLE ELECTRICAL EQUIPMENT
• 2.2.10. PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT
• 2.2.11. PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT
• 2.2.12. DISCONNECT AND CONNECT PUSHPULL TYPE COUPLER
• 2.2.12.1. METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSHPULL TYPE COUPLER
• 2.2.12.2. METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSHPULL TYPE COUPLER
• 2.2.12.3. METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSHPULL TYPE COUPLER
• 2.2.13. PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS
• 2.2.14. METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR
• 2.2.15. METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR
• 2.2.16. METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL
• 2.2.17. METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH
• 2.2.18. METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE
• 2.2.19. STANDARD TIGHTENING TORQUE TABLE
• 2.2.20. CONVERSION TABLE
• 2.2.21. ABBREVIATION LIST
• 3. SPECIFICATION
• 3.1. CONTENTS
• 3.2. SPECIFICATIONS
• 3.2.1. OUTLINE OF EXHAUST GAS REGULATION
• 3.2.1.1. SYSTEM DIAGRAM OF ENGINE CONFORMED TO TIER4 REGULATION
• 3.2.2. LIST OF APPLICABLE MACHINES 3D95E1
• 3.2.3. SPECIFICATIONS
• 3.2.3.1. SPECIFICATIONS SAA3D95E1(PC78US11, PC78US11E0, PC88MR11, PC88MR11E0)
• 3.2.4. ENGINE GENERAL VIEW
• 3.2.4.1. ENGINE GENERAL VIEW SAA3D95E1(PC78US11, PC78US11E0, PC88MR11, PC88MR11E0)
• 3.2.5. WEIGHT TABLE
• 3.2.5.1. WEIGHT TABLE 3D95E1
• 3.2.6. ENGINE PERFORMANCE CURVE
• 3.2.6.1. ENGINE PERFORMANCE CURVE SAA3D95E1 (PC78US11, PC78US11E0, PC88MR11, PC88MR11E0)
• 4. STRUCTURE AND FUNCTION
• 4.1. CONTENTS
• 4.2. ENGINE SYSTEM
• 4.2.1. LAYOUT OF ENGINE COMPONENTS
• 4.2.1.1. LAYOUT DRAWING OF ENGINE COMPONENTS
• 4.2.2. INTAKE AND EXHAUST SYSTEM PARTS
• 4.2.2.1. LAYOUT DRAWING OF INTAKE AND EXHAUST SYSTEM
• 4.2.2.2. INTAKE AND EXHAUST SYSTEM CIRCUIT DIAGRAM
• 4.2.2.3. FUNCTION OF INTAKE AND EXHAUST SYSTEM
• 4.2.2.4. AIR CLEANER
• 4.2.2.5. INTAKE AIR HEATER
• 4.2.3. ENGINE MAIN BODY PARTS
• 4.2.3.1. CYLINDER HEAD
• 4.2.3.2. CYLINDER BLOCK
• 4.2.3.3. MAIN DRIVE PARTS
• 4.2.3.4. TIMING GEAR
• 4.2.3.5. FRONT COVER
• 4.2.3.6. VALVE SYSTEM
• 4.2.3.7. FLYWHEEL AND FLYWHEEL HOUSING
• 4.2.4. TURBOCHARGER SYSTEM
• 4.2.4.1. TURBOCHARGER
• 4.2.4.2. EGR SYSTEM
• 4.2.4.3. EGR VALVE
• 4.2.4.4. EGR COOLER
• 4.2.4.5. HIGH EFFICIENCY BREATHER SYSTEM
• 4.2.4.6. HIGH EFFICIENCY BREATHER
• 4.2.4.7. EXHAUST THROTTLE VALVE
• 4.2.4.8. KDOC
• 4.2.4.9. KDPF
• 4.2.5. LUBRICATION SYSTEM
• 4.2.5.1. LAYOUT DRAWING OF LUBRICATION SYSTEM PARTS
• 4.2.5.2. LUBRICATION SYSTEM CIRCUIT DIAGRAM
• 4.2.5.3. ENGINE OIL PUMP
• 4.2.5.4. ENGINE OIL FILTER
• 4.2.5.5. ENGINE OIL COOLER
• 4.2.5.6. ENGINE OIL PAN
• 4.2.6. FUEL SYSTEM
• 4.2.6.1. LAYOUT DRAWING OF FUEL SYSTEM PARTS
• 4.2.6.2. FUEL SYSTEM CIRCUIT DIAGRAM
• 4.2.6.3. CRI SYSTEM
• 4.2.6.4. SUPPLY PUMP
• 4.2.6.5. COMMON RAIL
• 4.2.6.6. INJECTOR
• 4.2.6.7. FUEL PREFILTER
• 4.2.6.8. FUEL MAIN FILTER
• 4.2.7. COOLING SYSTEM
• 4.2.7.1. LAYOUT DRAWING OF COOLING SYSTEM PARTS
• 4.2.7.2. COOLING SYSTEM CIRCUIT DIAGRAM
• 4.2.7.3. DRIVE PULLEY
• 4.2.7.4. WATER PUMP
• 4.2.7.5. THERMOSTAT
• 4.3. ELECTRICAL SYSTEM
• 4.3.1. COMPONENT PARTS OF ELECTRICAL SYSTEM
• 4.3.1.1. ALTERNATOR
• 4.3.1.2. STARTING MOTOR
• 4.3.1.3. ENGINE WIRING HARNESS
• 4.3.1.4. ENGINE CONTROLLER
• 4.3.2. SENSOR
• 4.3.2.1. LAYOUT DRAWING OF ENGINE SENSOR
• 4.3.2.2. STRUCTURE OF AMBIENT PRESSURE SENSOR
• 4.3.2.3. FUNCTION OF AMBIENT PRESSURE SENSOR
• 4.3.2.4. STRUCTURE OF ENGINE OIL PRESSURE SWITCH
• 4.3.2.5. FUNCTION OF ENGINE OIL PRESSURE SWITCH
• 4.3.2.6. STRUCTURE OF CHARGE (BOOST) PRESSURE AND TEMPERATURE SENSOR
• 4.3.2.7. FUNCTION OF CHARGE (BOOST) PRESSURE AND TEMPERATURE SENSOR
• 4.3.2.8. STRUCTURE OF COOLANT TEMPERATURE SENSOR
• 4.3.2.9. FUNCTION OF COOLANT TEMPERATURE SENSOR
• 4.3.2.10. STRUCTURE OF NE (CRANKSHAFT) SPEED SENSOR
• 4.3.2.11. FUNCTION OF NE (CRANKSHAFT) SPEED SENSOR
• 4.3.2.12. STRUCTURE OF Bkup (CAM) SPEED SENSOR
• 4.3.2.13. FUNCTION OF Bkup (CAM) SPEED SENSOR
• 4.3.2.14. STRUCTURE OF COMMON RAIL PRESSURE SENSOR
• 4.3.2.15. FUNCTION OF COMMON RAIL PRESSURE SENSOR
• 4.3.2.16. STRUCTURE OF MASS AIR FLOW AND TEMPERATURE SENSOR
• 4.3.2.17. FUNCTION OF MASS AIR FLOW AND TEMPERATURE SENSOR
• 4.3.2.18. STRUCTURE OF AIR CLEANER CLOGGING SENSOR
• 4.3.2.19. FUNCTION OF AIR CLEANER CLOGGING SENSOR
• 4.3.2.20. STRUCTURE OF EGR VALVE (WITH BUILTIN POSITION SENSOR)
• 4.3.2.21. FUNCTION OF EGR VALVE (WITH BUILTIN POSITION SENSOR)
• 4.3.2.22. STRUCTURE OF EXHAUST THROTTLE VALVE (WITH BUILTIN POSITION SENSOR)
• 4.3.2.23. FUNCTION OF EXHAUST THROTTLE VALVE (WITH BUILTIN POSITION SENSOR)
• 5. STANDARD VALUE TABLE
• 5.1. CONTENTS
• 5.2. STANDARD VALUE TABLE FOR ENGINE
• 5.2.1. STANDARD VALUE TABLE FOR ENGINE SAA3D95E1 (PC78US11, PC78US11E0, PC88MR11, PC88MR11E0)
• 5.3. PERFORMANCE TEST STANDARD AND STANDARD FOR OPERATION OF ENGINE FOR BREAK IN PERIOD
• 5.3.1. PERFORMANCE TEST STANDARD AND STANDARD FOR OPERATION OF ENGINE FOR BREAK IN PERIOD SAA3D95E1 (PC78US11, PC78US11E0, PC88MR11, PC88MR11E0)
• 6. DISASSEMBLY AND ASSEMBLY
• 6.1. CONTENTS
• 6.2. RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY
• 6.2.1. HOW TO READ THIS MANUAL
• 6.2.2. COATING MATERIALS LIST
• 6.2.3. SPECIAL TOOLS LIST
• 6.2.4. SKETCHES OF SPECIAL TOOLS
• 6.3. ENGINE RELATED
• 6.3.1. DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY
• 6.3.1.1. DISASSEMBLE ENGINE GENERALLY
• 6.3.1.2. ASSEMBLE ENGINE GENERALLY
• 6.3.2. REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY
• 6.3.2.1. REMOVE SUPPLY PUMP ASSEMBLY
• 6.3.2.2. INSTALL SUPPLY PUMP ASSEMBLY
• 6.3.3. REMOVE AND INSTALL ENGINE FRONT OIL SEAL
• 6.3.3.1. REMOVE ENGINE FRONT OIL SEAL
• 6.3.3.2. INSTALL ENGINE FRONT OIL SEAL
• 7. MAINTENANCE STANDARD
• 7.1. CONTENTS
• 7.2. EXPLANATION OF TERMS FOR MAINTENANCE STANDARD
• 7.3. ENGINE SYSTEM
• 7.3.1. INTAKE AND EXHAUST SYSTEM PARTS
• 7.3.1.1. MAINTENANCE STANDARD OF TURBOCHARGER
• 7.3.2. ENGINE MAIN BODY PARTS
• 7.3.2.1. MAINTENANCE STANDARD OF CYLINDER HEAD
• 7.3.2.2. MAINTENANCE STANDARD OF CYLINDER BLOCK
• 7.3.2.3. MAINTENANCE STANDARD OF CRANKSHAFT
• 7.3.2.4. MAINTENANCE STANDARD OF PISTON
• 7.3.2.5. MAINTENANCE STANDARD OF CONNECTING ROD
• 7.3.2.6. MAINTENANCE STANDARD OF TIMING GEAR
• 7.3.2.7. MAINTENANCE STANDARD OF CAMSHAFT
• 7.3.2.8. MAINTENANCE STANDARD OF VALVE AND VALVE GUIDE
• 7.3.2.9. MAINTENANCE STANDARD OF ROCKER ARM
• 7.3.2.10. MAINTENANCE STANDARD OF TAPPET
• 7.3.2.11. MAINTENANCE STANDARD OF FLYWHEEL
• 7.3.3. LUBRICATION SYSTEM
• 7.3.3.1. MAINTENANCE STANDARD OF ENGINE OIL PUMP
• 8. INDEX