Komatsu D900 Series Engine D962K D963K Official Workshop Service Repair Manual

Komatsu D900 Series Engine D962K D963K Official Workshop Service Repair Manual

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This is the COMPLETE Official Service Repair Manual for the Komatsu Engine.
This manual contains deep information about maintaining, assembly, disassembly and servicing your Komatsu. 

This PDF file is Bookmarked and SEARCHABLE to make what you need easy to find. 

Models And Serials :

D943B
D962B
D963B
D963A2
D963A1
D962K
D963K

CONTENTS : 

Description 
Engine D 943 B, Injection pump side
D 943 B, Camshaft side 
D 962 B, Injection pump side 
D 962 B, Camshaft side 
D962 K, Injection pump side 
D 962 K, Camshaft side 
D 963 B, Injection pump side 
D 963 B, Camshaft side 
D 963 K, Injection pump side 
D 963 K, Camshaft side 
D 963 A 1, Injection pump side 
D 963 A 1, Camshaft side 
D963 A 2, Injection’pump side 
D 963 A 2, Camshaft side 
Fault finding chart
Engine speed, testing and adjusting 
Engine mountings, replacing, D 962 K Dozer 
Engine mountings, replacing, D 963 B, D 963 A l, D 963 A 2 
General technical data, repair values D943 8 
D 962 B
D 962 K
Page 5000 – 500 shows from 
which engine number import- D 963 B 
ant amendments have taken D 963 K 
place to the repair values.
D 963 A 1 
D 963 A 2 
Cylinder block
Cylinder liners, removing
Cylinder liners, refitting 
Rear crankshaft oil seal, replacing 
Side covers and gaskets, replacing 
Cylinder head, complete
Compression pressure test
Adjusting valve clearances
Air intake pipes and hoses, removing and refitting D 963 A 1,D 963 A 2 
Exhaust silencer, supports and gaskets, removing and
refitting D 962 B / D 962 K/ D 963 B / D 963 K
Air intake manifolds and hoses, removing and refitting
Cylinder head water pipes, removing and refitting
D 943 B / D 962B / D 962K / D963 K
Heat exchanger water pipes, replacing D 943 B/D 962 B/D 962 K/D 963 K
Cylinder head water pipes and hoses replacing
D 963 B / D 963 A 1/ D 963 A 2
Cab heater shut-off valve, removing, refitting and replacing
Rocker arms, rocker shafts and push rods, removing
Rocker arms, rocker shafts and push rods, refitting
Cylinder head complete, removing and refitting
Cylinder head, dismantling
Valve seat inserts, refitting
Valve seat inserts, machining (in situ)
Valves and seats, regrinding
Valve guides, refitting
Cylinder head, assembling
Pistons / connecting_rods, complete
Pistons/ connecting rods, removing
Fitting piston to connecting rod
Pistons/ connecting rods, refitting
Crankshaft, complete
Crankshaft, removing
Crankshaft, refitting
Engine timing gear
Front crankshaft oi I seal, replacing
Push rods, tappets and camshaft, removing
Fuel injection pump drive, removing
Fuel injection pump drive, dismantling and assembling
Fuel injection pump drive, dismantling and assembling D 963 A 2
Camshaft bearings, replacing
Tappets, push rods and camshaft refitting
Injection pump drive, refitting
Timing gear, setting
Timing case cover, sump, pulley and push rods, refitting
Checking the back lash and end float
Engine lubrication system
Oil circuit diagram D943 B
D 962 B / D 962 K
D963 K
D 963 B
D 963 A1/ D 963 A 2
OiI pump, pressure relief valve and piston cooling
nozzle, removing
Oil pump dismantling
Oil pump assembling
Oi I pump dismantled
Oil pump, pressure relief valve and piston cooling
nozzle, refitting
Oil flter complete and filter support removing and
refitting D 963 B/ D 963 K / D 963 A1/ D963 A 2
Orl filter base and support, dismantled
D 963 B / D 963 K / D 963 A 1 / D 963 A 2
Oil filter complete, removing and refitting
D 943 B /D962 B / D 962 K
OiI pipes and connections, repairing and replacing
Turbo supercharger oil feed pipes, removing and refitting
Oil sump and gasket, removing and refitting
Fuel injection system
Circuit diagrams of the fuel injection and cold-start systems
Changes to the fuel injection system
Function of the cold-start device installed in the fuel injection pump
Checking the commencement of injection
Setting the commencement of injection
Engine control, adjusting D 962 K
Accelerator cable, to adjust D 943 B / D962 B/
D 963 B / D963 A l / D 963 A 2
Fuel injection pump, removing
Fuel injection pump, refitting
Fuel injectors removing and refitting
Fuel injectors, testing and repairing
Injection pipes and fuel leak-off hoses, replacing
Glow plug, removing and refitting D 963 A l / D 963 A 2
Fuel feed pump, testing and replacing
Hand priming pump, testing and replacing
Engine accessory eqipment
Cooling fan, removing and refitting D 963 A 1 / D 963 A 2
Fan pulley, removing and refitting D 963 A 1 / D 963 A 2
Fan spindle bearing, removing and refitting D 963 A 1 / D 963 A 2
Fan pulley, replacing D 962. K
Fan spindle bearing, removing and refitting D 962K
Fan spindle bearing, dismantling and assembling D 962 K
Water pump pulley, replacing D 962 K
Water pump pulley, removing and refitting
D 963 B / D 963 A1/ D 963 A 2
V-belt tensioner, removing, refitting and reconditioning
D 963 K / D963 3/ D 963 A1/ D 963 A 2
Water pump, removing and refitting D 943 B / D 962K
Water pump, removing and refitting D 963B/ D 963 A1/ D 963 A 2
Water pump, dismantling and assembling D 943 B / D962 K
Fuel injection system
Circuit diagrams of the fuel injection and cold-start systems
Changes to the fuel injection system
Function of the cold-start device installed in the fuel injection pump
Checking the commencement of injection
Setting the commencement of injection
Engine control, adjusting D 962 K
Accelerator cable, to adjust D 943 B / D962 B/
D 963 B / D963 A l / D 963 A 2
Fuel injection pump, removing
Fuel injection pump, refitting
Fuel injectors removing and refitting
Fuel injectors, testing and repairing
Injection pipes and fuel leak-off hoses, replacing
Glow plug, removing and refitting D 963 A l / D 963 A 2
Fuel feed pump, testing and replacing
Hand priming pump, testing and replacing
Engine accessory eqipment
Cooling fan, removing and refitting D 963 A 1 / D 963 A 2
Fan pulley, removing and refitting D 963 A 1 / D 963 A 2
Fan spindle bearing, removing and refitting D 963 A 1 / D 963 A 2
Fan pulley, replacing D 962. K
Fan spindle bearing, removing and refitting D 962K
Fan spindle bearing, dismantling and assembling D 962 K
Water pump pulley, replacing D 962 K
Water pump pulley, removing and refitting
D 963 B / D 963 A1/ D 963 A 2
V-belt tensioner, removing, refitting and reconditioning
D 963 K / D963 3/ D 963 A1/ D 963 A 2
Water pump, removing and refitting D 943 B / D 962K
Water pump, removing and refitting D 963B/ D 963 A1/ D 963 A 2
Water pump, dismantling and assembling D 943 B / D962 K

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