Komatsu 70E-5, 76E-5 Series Diesel Engine Shop Manual SEBM037701

Description

• Model List:
  • 70E-5 Series Diesel Engine
  • 76E-5 Series Diesel Engine

• 1. COVER
• 2. CONTENTS
• 3. GENERAL
• 3.1. SPECIFICATIONS
• 3.2. ENGINE EXTERNAL VIEWS
• 3.3. STRUCTURAL DESCRIPTION
• 4. INSPECTION AND ADJUSTMENT
• 4.1. PERIODIC MAINTENANCE SCHEDULE
• 4.2. PERIODIC INSPECTION AND MAINTENANCE PROCEDURE
• 4.2.1. CHECK BEFORE DAILY OPERATION
• 4.2.2. INSPECTION AFTER INITIAL 50 HOURS OPERATION
• 4.2.3. INSPECTION EVERY 50 HOURS
• 4.2.4. INSPECTION EVERY 250 HOURS OR 3 MONTHS
• 4.2.5. INSPECTION EVERY 500 HOURS OR 6 MONTHS
• 4.2.6. INSPECTION EVERY 1,000 HOURS OR ONE YEAR
• 4.2.7. INSPECTION EVERY 2000 HOURS OR 2 YEARS
• 4.3. ADJUSTING THE NOLOAD MAXIMUM OR MINIMUM SPEED
• 4.4. SENSOR INSPECTION
• 4.4.1. OIL PRESSURE SWITCH
• 4.4.2. THERMO SWITCH
• 4.5. WATER LEAK CHECK IN COOLING WATER SYSTEM
• 4.6. RADIATOR CAP INSPECTION
• 4.7. THERMOSTAT INSPECTION
• 4.8. ADJUSTING OPERATION
• 4.9. LONG STORAGE
• 5. TROUBLESHOOTING
• 5.1. PREPARATION BEFORE TROUBLESHOOTING
• 5.2. QUICK REFERENCE TABLE FOR TROUBLESHOOTING
• 5.3. TROUBLESHOOTING BY MEASURING COMPRESSION PRESSURE
• 6. DISASSEMBLY, INSPECTION AND REASSEMBLY OF ENGINES
• 6.1. COMPLETE DISASSEMBLY AND REASSEMBLY
• 6.1.1. INTRODUCTION
• 6.1.2. SPECIAL SERVICE TOOLS
• 6.1.3. COMPLETE DISASSEMBLY
• 6.1.4. PRECAUTIONS BEFORE AND DURING REASSEMBLY
• 6.1.5. ADJUSTING OPERATION
• 6.2. CYLINDER HEAD DISASSEMBLY, INSPECTION AND REASSEMBLY
• 6.2.1. COMPONENTS (2VALVE CYLINDER HEAD)
• 6.2.2. DISASSEMBLY PROCEDURE
• 6.2.3. REASSEMBLY PROCEDURE
• 6.2.4. SERVICING POINTS
• 6.2.5. PARTS INSPECTION AND MEASUREMENT
• 6.2.6. VALVE SEAT CORRECTION
• 6.2.7. VALVE GUIDE REPLACEMENT
• 6.2.8. VALVE STEM SEAL REPLACEMENT
• 6.3. GEAR TRAIN AND CAMSHAFT
• 6.3.1. COMPONENTS
• 6.3.2. DISASSEMBLY PROCEDURE
• 6.3.3. REASSEMBLY PROCEDURE
• 6.3.4. SERVICING POINTS
• 6.3.5. PARTS INSPECTION AND MEASUREMENT
• 6.3.6. OIL SEAL REPLACEMENT (GEAR CASE SIDE)
• 6.3.7. CAMSHAFT BUSHING REPLACEMENT
• 6.4. CYLINDER BLOCK
• 6.4.1. COMPONENTS
• 6.4.2. DISASSEMBLY PROCEDURE
• 6.4.3. REASSEMBLY PROCEDURE
• 6.4.4. SERVICING POINTS
• 6.4.5. PARTS INSPECTION AND MEASUREMENT
• 6.4.6. CYLINDER BORE CORRECTION
• 6.4.7. PISTON PIN METAL REPLACEMENT
• 6.4.8. OIL SEAL REPLACEMENT (FLYWHEEL HOUSING SIDE)
• 7. LUBRICATION SYSTEM
• 7.1. LUBRICATION SYSTEM DIAGRAM
• 7.2. TROCHOID PUMP COMPONENTS
• 7.3. DISASSEMBLY (REVERSE THE PROCEDURE BELOW FOR ASSEMBLY)
• 7.4. SERVICING POINTS
• 7.5. PARTS INSPECTION AND MEASUREMENT
• 8. COOLING SYSTEM
• 8.1. COOLING WATER SYSTEM
• 8.2. COOLING WATER PUMP COMPONENTS
• 8.3. DISASSEMBLY (REVERSE THE PROCEDURE BELOW FOR ASSEMBLY)
• 8.4. SERVICING POINTS
• 9. FUEL INJECTION PUMP/GOVERNOR
• 9.1. INTRODUCTION
• 9.2. FUEL INJECTION PUMP
• 9.2.1. FUEL SYSTEM DIAGRAM
• 9.2.2. EXTERNAL VIEW AND COMPONENTS
• 9.2.3. DISASSEMBLY PROCEDURE
• 9.2.4. ASSEMBLY PROCEDURE
• 9.2.5. CONFIRMATION AND ADJUSTMENT OF FUEL INJECTION TIMING
• 9.2.6. CONFIRMATION AND ADJUSTMENT OF NOLOAD MAXIMUM AND MINIMUM SPEED
• 10. THE SPECIFICATIONS OF A STARTING MOTOR AND THE CHARACTERISTICS
• 10.1. THE SPECIFICATIONS AND THE CHARACTERISTICS
• 10.1.1. SPECIFICATIONS
• 10.1.2. CHARACTERISTICS
• 10.2. THE STRUCTURE OF A STARTING MOTOR AND THE WIRING DIAGRAM
• 10.2.1. STRUCTURE
• 10.2.2. WIRING DIAGRAM OF A STARTING MOTOR
• 10.3. PERFORMANCE
• 11. ALTERNATOR
• 11.1. ALTERNATOR
• 11.1.1. SPECIFICATIONS
• 11.1.2. STRUCTURE
• 11.1.3. WIRING DIAGRAM
• 11.1.4. STANDARD OUTPUT CHARACTERISTICS
• 11.1.5. INSPECTION
• 11.2. ALTERNATOR
• 11.2.1. COMPONENTS
• 11.2.2. SPECIFICATIONS
• 11.2.3. WIRING DIAGRAM.
• 11.2.4. STANDARD OUTPUT CHARACTERISTICS
• 11.2.5. INSPECTION
• 11.2.6. TROUBLESHOOTING
• 12. ELECTRIC WIRING
• 12.1. ELECTRIC WIRING DIAGRAM
• 12.2. PRECAUTION ON ELECTRIC WIRING
• 12.2.1. ALTERNATOR
• 12.2.2. STARTING MOTOR
• 12.2.3. CURRENT LIMITER
• 12.2.4. SECTION AREA AND RESISTANCE OF ELECTRIC WIRE
• 13. SERVICE STANDARDS
• 13.1. ENGINE TUNING
• 13.2. ENGINE BODY
• 13.2.1. CYLINDER HEAD
• 13.2.2. GEAR TRAIN AND CAMSHAFT
• 13.2.3. CYLINDER BLOCK
• 13.3. LUBRICATING OIL SYSTEM (TROCHOID PUMP)
• 14. TIGHTENING TORQUE FOR BOLTS AND NUTS
• 14.1. TIGHTENING TORQUES FOR MAIN BOLTS AND NUTS
• 14.2. TIGHTENING TORQUES FOR STANDARD BOLTS AND NUTS