Komatsu 76E-5 Series Diesel Engine Shop Manual SEBM037700

Description

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

• 1. MAIN MENU
• 2. COVER
• 3. PREFACE
• 4. SAFETY LABELS
• 5. SAFETY PRECAUTIONS
• 6. PRECAUTIONS FOR SERVICE WORK
• 7. HOW TO READ THIS MANUAL
• 8. APPLICATION CATEGORY
• 9. APPLICABLE MACHINE, SERIAL NUMBER
• 10. CONTENTS
• 11. GENERAL
• 11.1. SPECIFICATIONS
• 11.2. ENGINE EXTERNAL VIEWS
• 11.3. STRUCTURAL DESCRIPTION
• 12. INSPECTION AND ADJUSTMENT
• 12.1. PERIODIC MAINTENANCE SCHEDULE
• 12.2. PERIODIC INSPECTION AND MAINTENANCE PROCEDURE
• 12.2.1. CHECK BEFORE DAILY OPERATION
• 12.2.2. INSPECTION AFTER INITIAL 50 HOURS OPERATION
• 12.2.3. INSPECTION EVERY 50 HOURS
• 12.2.4. INSPECTION EVERY 250 HOURS OR 3 MONTHS
• 12.2.5. INSPECTION EVERY 500 HOURS OR 6 MONTHS
• 12.2.6. INSPECTION EVERY 1000 HOURS OR ONE YEAR
• 12.2.7. INSPECTION EVERY 2000 HOURS OR 2 YEARS
• 12.3. ADJUSTING THE NOLOAD MAXIMUM OR MINIMUM SPEED
• 12.4. SENSOR INSPECTION
• 12.4.1. OIL PRESSURE SWITCH
• 12.4.2. THERMO SWITCH
• 12.5. WATER LEAK CHECK IN COOLING WATER SYSTEM
• 12.6. RADIATOR CAP INSPECTION
• 12.7. THERMOSTAT INSPECTION
• 12.8. ADJUSTING OPERATION
• 12.9. LONG STORAGE
• 13. TROUBLESHOOTING
• 13.1. PREPARATION BEFORE TROUBLSHOOTING
• 13.2. QUICK REFERENCE TABLE FOR TROUBLESHOOTING
• 13.3. TROUBLESHOOTING BY MEASURING COMPRESSION PRESSURE
• 14. DISASSEMBLY, INSPECTION AND REASSEMBLY OF ENGINES
• 14.1. COMPLETE DISASSEMBLY AND REASSEMBLY
• 14.1.1. INTRODUCTION
• 14.1.2. SPECIAL SERVICE TOOLS
• 14.1.3. COMPLETE DISASSEMBLY
• 14.1.4. PRECAUTIONS BEFORE AND DURING REASSEMBLY
• 14.1.5. ADJUSTING OPERATION
• 14.2. CYLINDER HEAD DISASSEMBLY, INSPECTION AND REASSEMBLY
• 14.2.1. COMPONENTS (2VALVE CYLINDER HEAD)
• 14.2.2. DISASSEMBLY PROCEDURE
• 14.2.3. REASSEMBLY PROCEDURE
• 14.2.4. SERVICING POINTS
• 14.2.5. PARTS INSPECTION AND MEASUREMENT
• 14.2.6. VALVE SEAT CORRECTION
• 14.2.7. VALVE GUIDE REPLACEMENT
• 14.2.8. VALVE STEM SEAL REPLACEMENT
• 14.3. GEAR TRAIN AND CAMSHAFT
• 14.3.1. COMPONENTS
• 14.3.2. DISASSEMBLY PROCEDURE
• 14.3.3. REASSEMBLY PROCEDURE
• 14.3.4. SERVICING POINTS
• 14.3.5. PARTS INSPECTION AND MEASUREMENT
• 14.3.6. OIL SEAL REPLACEMENT (GEAR CASE SIDE)
• 14.3.7. CAMSHAFT BUSHING REPLACEMENT
• 14.4. CYLINDER BLOCK
• 14.4.1. COMPONENTS
• 14.4.2. DISASSEMBLY PROCEDURE
• 14.4.3. REASSEMBLY PROCEDURE
• 14.4.4. SERVICING POINTS
• 14.4.5. PARTS INSPECTION AND MEASUREMENT
• 14.4.6. CYLINDER BORE CORRECTION
• 14.4.7. PISTION PIN METAL REPLACEMENT
• 14.4.8. OIL SEAL REPLACEMENT (FLYWHEEL HOUSING SIDE)
• 15. LUBRICATION SYSTEM
• 15.1. LUBRICATION SYSTEM DIAGRAM
• 15.2. TROCHOID PUMP COMPONENTS
• 15.3. DISASSEMBLY (REVERSE THE PROCEDURE BLEWO FOR ASSEMBLY)
• 15.4. SERVICING POINTS
• 15.5. PARTS INSPECTION AND MEASUREMENT
• 16. COOLING SYSTEM
• 16.1. COOLING WATER SYSTEM
• 16.2. COOLING WATER PUMP COMPONENTS
• 16.3. DISASSEMBLY (REVERSE THE PROCEDURE BELOW FOR ASSEMBLY)
• 16.4. SERVICING POINTS
• 17. FUEL INJECTION PUMP/GOVERNOR
• 17.1. INTRODUCTION
• 17.2. FUEL INJECTION PUMP
• 17.2.1. FUEL SYSTEM DIAGRAM
• 17.2.2. EXTERNAL VIEW AND COMPONENTS
• 17.2.3. DISASSEMBLY PROCEDURE
• 17.2.4. ASSEMBLY PROCEDURE
• 17.2.5. CONFIRMATION AND ADJUSTMENT OF FUEL INJECTION TIMING
• 17.2.6. CONFIRMATIONAND ADJUSTMENT OF NOLOAD MAXIMUM AND MINIMUM SPEED
• 18. THE SPECIFICATIONS OF A STARTING MOTOR AND THE CHARACTERISTICS
• 18.1. THE SPECIFICATIONS AND THE CHARACTERISTICS
• 18.1.1. SPECIFICATIONS
• 18.1.2. CHARACTERISTICS
• 18.2. THE STRUCTURE OF A STARTING MOTOR AND THE WIRING DIAGRAM
• 18.2.1. STRUCTURE
• 18.2.2. WIRING DIAGRAM OF A STARTING MOTOR
• 18.3. PERFORMANCE
• 19. ALTERNATOR
• 19.1. ALTERNATOR
• 19.1.1. SPECIFICATIONS
• 19.1.2. STRUCTURE
• 19.1.3. WIRING DIAGRAM
• 19.1.4. STANDARD OUTPUT CHARACTERISTICS
• 19.1.5. INSPECTION
• 19.2. TROUBLESHOOTING
• 19.3. ALTERNATOR
• 19.3.1. COMPONENTS
• 19.3.2. SPECIFICATIONS
• 19.3.3. WIRING DIAGRAM
• 19.3.4. STANDARD OUTPUT CHARACTERISTICS
• 19.3.5. INSPECTION
• 19.3.6. TROUBLESHOOTING
• 20. ELECTRIC WIRING
• 20.1. ELECTRIC WIRING DIAGRAM
• 20.2. PRECAUTION ON ELECTRIC WIRING
• 20.2.1. ALTERNATOR
• 20.2.2. STARTING MOTOR
• 20.2.3. CURRENT LIMITOR
• 20.2.4. SECTION AREA AND RESISTANCE OF ELECTRIC WIRE
• 21. SERVICE STANDARDS
• 21.1. ENGINE TUNING
• 21.2. ENGINE BODY
• 21.2.1. CYLINDER HEAD
• 21.2.2. GEAR TRAIN AND CAMSHAFT
• 21.2.3. CYLINDER BLOCK
• 21.3. LUBRICATING OIL SYSTEM (TROCHIOD PUMP)
• 22. TIGHTENING TORQUE FOR BOLTS AND NUTS
• 22.1. TIGHTENING TOQUES FOR MAIN BOLTS AND NUTS
• 22.2. TIGHTENING TORQUES FOR STANDARD BOLTS AND NUTS