Complete service repair manual with Electrical Wiring Diagrams for Komatsu Diesel Engines 70E-5, 76E-5 Series, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Komatsu 70E-5, 76E-5 Series Diesel Engines workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
SEBM037701 – 70E-5, 76E-5 Series Diesel Engine Shop Manual.pdf
PRODUCT DETAILS:
Total Pages: 144 pages
File Format: PDF
Language: English
MAIN SECTIONS
1. GENERAL… 1-1
2. INSPECTION AND ADJUSTMENT… 2-1
3. TROUBLESHOOTING … 3-1
4. DISASSEMBLY, INSPECTION AND REASSEMBLY OF ENGINES … 4-1
5. LUBRICATION SYSTEM … 5-1
6. COOLING SYSTEM … 6-1
7. FUEL INJECTION PUMP / GOVERNOR … 7-1
8. SPECIFICATIONS OF A STARTING MOTOR … 8-1
9. ALTERNATOR… 9-1
10. ELECTRIC WIRING … 10-1
11. SERVICE STANDARDS … 11-1
12. TIGHTENING TORQUE FOR BOLTS AND NUTS … 12-1
COVER…..1
CONTENTS…..15
1. GENERAL…..16
1.1 SPECIFICATIONS…..17
1.2 ENGINE EXTERNAL VIEWS…..19
1.3 STRUCTURAL DESCRIPTION…..20
2. INSPECTION AND ADJUSTMENT…..21
2.1 PERIODIC MAINTENANCE SCHEDULE…..22
2.2 PERIODIC INSPECTION AND MAINTENANCE PROCEDURE…..23
2.2.1 CHECK BEFORE DAILY OPERATION …..23
2.2.2 INSPECTION AFTER INITIAL 50 HOURS OPERATION …..25
2.2.3 INSPECTION EVERY 50 HOURS…..28
2.2.4 INSPECTION EVERY 250 HOURS OR 3 MONTHS…..32
2.2.5 INSPECTION EVERY 500 HOURS OR 6 MONTHS…..35
2.2.6 INSPECTION EVERY 1,000 HOURS OR ONE YEAR…..37
2.2.7 INSPECTION EVERY 2000 HOURS OR 2 YEARS…..43
2.3 ADJUSTING THE NO-LOAD MAXIMUM OR MINIMUM SPEED…..45
2.4 SENSOR INSPECTION…..46
2.4.1 OIL PRESSURE SWITCH…..46
2.4.2 THERMO SWITCH…..46
2.5 WATER LEAK CHECK IN COOLING WATER SYSTEM…..46
2.6 RADIATOR CAP INSPECTION…..47
2.7 THERMOSTAT INSPECTION …..47
2.8 ADJUSTING OPERATION …..48
2.9 LONG STORAGE…..48
3. TROUBLESHOOTING…..49
3.1 PREPARATION BEFORE TROUBLESHOOTING…..50
3.2 QUICK REFERENCE TABLE FOR TROUBLESHOOTING …..51
3.3 TROUBLESHOOTING BY MEASURING COMPRESSION PRESSURE…..54
4. DISASSEMBLY, INSPECTION AND REASSEMBLY OF ENGINES…..56
4.1 COMPLETE DISASSEMBLY AND REASSEMBLY…..57
4.1.1 INTRODUCTION…..57
4.1.2 SPECIAL SERVICE TOOLS…..58
4.1.3 COMPLETE DISASSEMBLY…..63
4.1.4 PRECAUTIONS BEFORE AND DURING REASSEMBLY…..67
4.1.5 ADJUSTING OPERATION …..67
4.2 CYLINDER HEAD: DISASSEMBLY, INSPECTION AND REASSEMBLY…..68
4.2.1 COMPONENTS (2-VALVE CYLINDER HEAD)…..68
4.2.2 DISASSEMBLY PROCEDURE…..69
4.2.3 REASSEMBLY PROCEDURE…..69
4.2.4 SERVICING POINTS…..70
4.2.5 PARTS INSPECTION AND MEASUREMENT…..74
4.2.6 VALVE SEAT CORRECTION …..78
4.2.7 VALVE GUIDE REPLACEMENT …..79
4.2.8 VALVE STEM SEAL REPLACEMENT…..80
4.3 GEAR TRAIN AND CAMSHAFT…..81
4.3.1 COMPONENTS…..81
4.3.2 DISASSEMBLY PROCEDURE…..81
4.3.3 REASSEMBLY PROCEDURE…..82
4.3.4 SERVICING POINTS…..82
4.3.5 PARTS INSPECTION AND MEASUREMENT …..85
4.3.6 OIL SEAL REPLACEMENT (GEAR CASE SIDE)…..86
4.3.7 CAMSHAFT BUSHING REPLACEMENT …..86
4.4 CYLINDER BLOCK…..87
4.4.1 COMPONENTS…..87
4.4.2 DISASSEMBLY PROCEDURE…..88
4.4.3 REASSEMBLY PROCEDURE…..88
4.4.4 SERVICING POINTS…..88
4.4.5 PARTS INSPECTION AND MEASUREMENT…..92
4.4.6 CYLINDER BORE CORRECTION…..101
4.4.7 PISTON PIN METAL REPLACEMENT …..102
4.4.8 OIL SEAL REPLACEMENT (FLYWHEEL HOUSING SIDE)…..102
5. LUBRICATION SYSTEM …..103
5.1 LUBRICATION SYSTEM DIAGRAM…..104
5.2 TROCHOID PUMP COMPONENTS…..105
5.3 DISASSEMBLY (REVERSE THE PROCEDURE BELOW FOR ASSEMBLY)…..105
5.4 SERVICING POINTS…..105
5.5 PARTS INSPECTION AND MEASUREMENT …..106
6. COOLING SYSTEM …..107
6.1 COOLING WATER SYSTEM …..108
6.2 COOLING WATER PUMP COMPONENTS…..108
6.3 DISASSEMBLY (REVERSE THE PROCEDURE BELOW FOR ASSEMBLY)…..109
6.4 SERVICING POINTS…..109
7. FUEL INJECTION PUMP/GOVERNOR…..110
7.1 INTRODUCTION …..111
7.2 FUEL INJECTION PUMP …..111
7.2.1 FUEL SYSTEM DIAGRAM…..111
7.2.2 EXTERNAL VIEW AND COMPONENTS…..112
7.2.3 DISASSEMBLY PROCEDURE…..113
7.2.4 ASSEMBLY PROCEDURE…..113
7.2.5 CONFIRMATION AND ADJUSTMENT OF FUEL INJECTION TIMING…..113
7.2.6 CONFIRMATION AND ADJUSTMENT OF NO-LOAD MAXIMUM AND MINIMUM SPEED…..113
8. THE SPECIFICATIONS OF A STARTING MOTOR AND THE CHARACTERISTICS…..114
8.1 THE SPECIFICATIONS AND THE CHARACTERISTICS…..115
8.1.1 SPECIFICATIONS…..115
8.1.2 CHARACTERISTICS…..115
8.2 THE STRUCTURE OF A STARTING MOTOR AND THE WIRING DIAGRAM…..116
8.2.1 STRUCTURE…..116
8.2.2 WIRING DIAGRAM OF A STARTING MOTOR…..117
8.3 PERFORMANCE…..117
9. ALTERNATOR…..118
9.1 20A ALTERNATOR…..119
9.1.1 SPECIFICATIONS…..119
9.1.2 STRUCTURE…..120
9.1.3 WIRING DIAGRAM…..121
9.1.4 STANDARD OUTPUT CHARACTERISTICS…..121
9.1.5 INSPECTION…..122
9.2 40A ALTERNATOR …..123
9.2.1 COMPONENTS…..123
9.2.2 SPECIFICATIONS…..124
9.2.3 WIRING DIAGRAM…..124
9.2.4 STANDARD OUTPUT CHARACTERISTICS …..125
9.2.5 INSPECTION…..125
9.2.6 TROUBLESHOOTING …..126
10.ELECTRIC WIRING …..127
10.1 ELECTRIC WIRING DIAGRAM…..128
10.2 PRECAUTION ON ELECTRIC WIRING…..130
10.2.1 ALTERNATOR…..130
10.2.2 STARTING MOTOR…..131
10.2.3 CURRENT LIMITER…..132
10.2.4 SECTION AREA AND RESISTANCE OF ELECTRIC WIRE…..133
11.SERVICE STANDARDS…..134
11.1 ENGINE TUNING…..135
11.2 ENGINE BODY…..136
11.2.1 CYLINDER HEAD…..136
11.2.2 GEAR TRAIN AND CAMSHAFT…..137
11.2.3 CYLINDER BLOCK …..138
11.3 LUBRICATING OIL SYSTEM (TROCHOID PUMP)…..141
12.TIGHTENING TORQUE FOR BOLTS AND NUTS…..142
12.1 TIGHTENING TORQUES FOR MAIN BOLTS AND NUTS…..143
12.2 TIGHTENING TORQUES FOR STANDARD BOLTS AND NUTS…..144
Komatsu 70E-5, 76E-5 Series Diesel Engine Repair Service Manuals