1997 Komatsu 95 Series Diesel Engine Shop Manual SEBE61460114 – PDF DOWNLOAD

1997 Komatsu 95 Series Diesel Engine Shop Manual SEBE61460114 – PDF DOWNLOAD

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1997 Komatsu 95 Series Diesel Engine Shop Manual SEBE61460114 – PDF DOWNLOAD

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1997 Komatsu 95 Series Diesel Engine Shop Manual SEBE61460114 – PDF DOWNLOAD

FOREWORD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by g1vmg the
serviceman an accurate understanding of the product and by showing him the correct way to perform
repairs and make judgements. Make sure you understand the contents of this manual and use it to full
effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a
service workshop. For ease of understanding, the manual is divided into the following chapters; these
chapters are further divided into the each main group of components.
STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give
an understanding of the structure, but also serves as reference material for troubleshooting.
TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as
adjustments to be made at completion of the checks and repairs.
Troubleshooting charts correlating “Problems” to “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling or
assembling each component, as well as precautions to be taken for these operations.
MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.

TABLE OF CONTENTS:

1997 Komatsu 95 Series Diesel Engine Shop Manual SEBE61460114 – PDF DOWNLOAD

COVER…………………………………………………………………………………………… 1
CONTENTS………………………………………………………………………………………… 2
01 GENERAL………………………………………………………………………………………. 25
GENERAL VIEW…………………………………………………………………………………. 26
SPECIFICATIONS……………………………………………………………………………….. 28
GENERAL ASSEMBLY DRAWING………………………………………………………………………. 50
ENGINE PERFORMANCE CURVE………………………………………………………………………. 92
WEIGHT TABLE………………………………………………………………………………….147
11 STRUCTURE AND FUNCTION………………………………………………………………………….149
GENERAL STRUCTURE……………………………………………………………………………..150
INTAKE AND EXHAUST SYSTEM………………………………………………………………………160
INTAKE AND EXHAUST SYSTEM…………………………………………………………………..160
FTG AIR CLEANER……………………………………………………………………………175
TURBOCHARGER………………………………………………………………………………178
AFTER-COOLER………………………………………………………………………………185
ENGINE BODY…………………………………………………………………………………..187
CYLINDER HEAD……………………………………………………………………………..187
VALVE SYSTEM………………………………………………………………………………205
CYLINDER BLOCK…………………………………………………………………………….213
CYLINDER LINER (FOR REPAIR ONLY)…………………………………………………………….219
MAIN CIRCULATION SYSTEM…………………………………………………………………….220
TIMING GEAR……………………………………………………………………………….237
FLYWHEEL AND FLYWHEEL HOUSING……………………………………………………………….243
LUBRICATION SYSTEM…………………………………………………………………………….247
LUBRICATION SYSTEM CHART……………………………………………………………………247
OIL PUMP………………………………………………………………………………….251
OIL FILTER………………………………………………………………………………..252
OIL FILTER MOUNT (FOR PC200,220-5)…………………………………………………………..253
OIL COOLER………………………………………………………………………………..254
FUEL SYSTEM…………………………………………………………………………………..256
FUEL SYSTEM CHART………………………………………………………………………….256
FUEL INJECTION PUMP………………………………………………………………………..268
OUTLINE OF ELECTRONIC GOVERNOR SYSTEM………………………………………………………..283
SYSTEM ELECTRICAL CIRCUIT DIAGRAM……………………………………………………………286
LOAD DETECTION SYSTEM (OPTION)………………………………………………………………290
LOAD DETECTOR SYSTEM (OPTION)……………………………………………………………….291
SYSTEM STRUCTURE DIAGRAM (3-PHASE CURRENT)……………………………………………………292
GOVERNOR………………………………………………………………………………….297
FEED PUMP…………………………………………………………………………………301
FUEL INJECTION NOZZLE………………………………………………………………………303
FUEL CUT SOLENOID………………………………………………………………………….306
ENGINE STOP MOTOR………………………………………………………………………….309
FUEL FILTER……………………………………………………………………………….314
WATER SEPARATOR……………………………………………………………………………315
COOLING SYSTEM………………………………………………………………………………..316
COOLING SYSTEM CHART……………………………………………………………………….316
WATER PUMP………………………………………………………………………………..319
CORROSION RESISTOR (OPTION)…………………………………………………………………322
THERMOSTAT AND FAN DRIVE……………………………………………………………………323
EXHAUST BRAKE……………………………………………………………………………..330
SOLENOID VALVE…………………………………………………………………………….331
ELECTRICAL SYSTEM……………………………………………………………………………..333
ALTERNATOR………………………………………………………………………………..333
STARTING MOTOR…………………………………………………………………………….342
ELECTRICAL INTAKE AIR HEATER………………………………………………………………..348
ACCESSORY…………………………………………………………………………………….352
AIR COMPRESSOR…………………………………………………………………………….352
12 TESTING AND ADJUSTING…………………………………………………………………………..354
INTAKE AND EXHAUST SYSTEM………………………………………………………………………355
ADJUSTING VALVE CLEARANCE…………………………………………………………………..355
MEASURING EXHAUST GAS COLOR…………………………………………………………………357
ENGINE BODY…………………………………………………………………………………..358
MEASURING COMPRESSION PRESSURE………………………………………………………………358
MEASURING BLOW-BY PRESSURE………………………………………………………………….359
ADJUSTING ENGINE SPEED SENSOR……………………………………………………………….360
FUEL SYSTEM…………………………………………………………………………………..361
CHECKING AND ADJUSTING FUEL INJECTION TIMING………………………………………………….361
ADJUSTING GOVERNOR (3D95S-W-1)………………………………………………………………370
TESTING AND ADJUSTING FUEL CUT SOLENOID ……………………………………………………..373
PROCEDURE FOR ADJUSTING ENGINE STOP MOTOR CABLE……………………………………………….378
ADJUSTING FUEL INJECTION PRESSURE (CRACKING PRESSURE)………………………………………….380
LUBRICATION SYSTEM…………………………………………………………………………….383
MEASURING OIL PRESSURE……………………………………………………………………..383
MEASURING OIL TEMPERATURE…………………………………………………………………..384
COOLING SYSTEM………………………………………………………………………………..385
MEASURING WATER TEMPERATURE…………………………………………………………………385
TESTING AND ADJUSTING FAN BELT TENSION……………………………………………………….386
FUEL INJECTION PUMP CALIBRATION DATA…………………………………………………………….387
PERFORMANCE TEST………………………………………………………………………………505
RUN-IN STANDARD……………………………………………………………………………505
PERFORMANCE TEST CRITERIA…………………………………………………………………..513
TESTING AND ADJUSTING TOOL LIST……………………………………………………………..533
TESTING AND ADJUSTING DATA………………………………………………………………….534
TROUBLESHOOTING……………………………………………………………………………….556
METHOD OF USING TROUBLESHOOTING CHART………………………………………………………..557
POINTS TO REMEMBER WHEN TROUBLESHOOTING………………………………………………………561
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)…………………………………..562
S-2 ENGINE DOES NOT START…………………………………………………………………..563
① ENGINE DOES NOT TURN………………………………………………………………….563
② ENGINE TURNS BUT NO EXHAUST GAS COMES OUT (FUEL IS NOT BEING INJECTED)……………………..564
③ EXHAUST GAS COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)……………………565
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)……………………………………….566
S-4 ENGINE STOPS DURING OPERATIONS…………………………………………………………..567
S-5 ENGINE DOES NOT ROTATE SMOOTHLY………………………………………………………….568
S-6 ENGINE LACKS OUTPUT (NO POWER)…………………………………………………………..569
S-7 EXHAUST GAS IS BLACK (INCOMPLETE COMBUSTION)………………………………………………570
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BLUE)………………………………………571
S-9 OIL BECOMES CONTAMINATED QUICKLY…………………………………………………………572
S-10 FUEL CONSUMPTION IS EXCESSIVE…………………………………………………………..573
S-11 OIL IS IN COOLING WATER,OR WATER SPURTS BACK,OR WATER LEVEL GOES DOWN……………………….574
S-12 OIL PRESSURE LAMP LIGHTS UP (DROP IN OIL PRESSURE)………………………………………..575
S-13 OIL LEVEL RISES……………………………………………………………………….576
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)………………………………………….577
S-15 ABNORMAL NOISE IS MADE…………………………………………………………………578
S-16 VIBRATION IS EXCESSIVE…………………………………………………………………579
S-17 DIAGNOSIS OF ELECTRONICAL GOVERNOR BY DIAGNOSIS DISPLAY (ELECTRONICAL GOVERNOR MADE BY ZEXEL)….580
13 DISASSEMBLY AND ASSEMBLY………………………………………………………………………..596
GENERAL DISASSEMBLY AND ASSEMBLY (3D95S-W-1)……………………………………………………..597
GENERAL DISASSEMBLY (3D95S-W-1) ……………………………………………………………598
1. FAN,FAN PULLEY………………………………………………………………………598
2. ALTERNATOR………………………………………………………………………….598
3. STARTING MOTOR………………………………………………………………………599
4. WATER PUMP………………………………………………………………………….599
5. FILTER,LEVEL GAUGE…………………………………………………………………..599
6. FUEL FILTER,INJECTION TUBLE…………………………………………………………..599
7. NOZZLE HOLDER……………………………………………………………………….599
8. GLOW PLUG…………………………………………………………………………..599
9. FUEL INJECTION PUMP………………………………………………………………….599
10. CYLINDER HEAD COVER…………………………………………………………………600
11. ROCKER ARM…………………………………………………………………………600
12. PUSH RODS………………………………………………………………………….600
13. CYLINDER HEAD ASSEMBLY………………………………………………………………600
14. FLYWHEEL…………………………………………………………………………..601
15. HOUSING……………………………………………………………………………601
16. CRANKSHAFT PULLEY…………………………………………………………………..601
17. OIL PAN……………………………………………………………………………601
18. OIL SUCTION PIPE……………………………………………………………………601
19. GEAR COVER…………………………………………………………………………602
20. IDLER GEAR…………………………………………………………………………602
21. OIL PUMP…………………………………………………………………………..602
22. CAMSHAFT ASSEMBLY…………………………………………………………………..602
23. PISTON,CONNECTING ROD ASSEMBLY……………………………………………………….602
24. MAIN CAP…………………………………………………………………………..604
25. CRANKSHAFT…………………………………………………………………………604
26. TAPPET…………………………………………………………………………….604
GENERAL ASSEMBLY…………………………………………………………………………..605
1. TAPPET……………………………………………………………………………..605
2. CAMSHAFT ASSEMBLY……………………………………………………………………605
3. CRANKSHAFT………………………………………………………………………….605
4. MAIN CAP……………………………………………………………………………606
5. PISTON,CONNECTING ROD ASSEMBLY………………………………………………………..607
6. OIL PUMP……………………………………………………………………………609
7. IDLER GEAR………………………………………………………………………….609
8. GEAR COVER………………………………………………………………………….610
9. OIL SUCTION PIPE…………………………………………………………………….610
10. OIL PAN……………………………………………………………………………610
11. CRANKSHAFT PULLEY…………………………………………………………………..610
12. HOUSING……………………………………………………………………………611
13. FLYWHEEL…………………………………………………………………………..611
14. CYLINDER HEAD………………………………………………………………………611
15. PUSH RODS………………………………………………………………………….613
16. ROCKER ARM…………………………………………………………………………613
17. ADJUSTING VALVE CLEARANCE……………………………………………………………614
18. CYLINDER HEAD COVER…………………………………………………………………614
19. FUEL INJECTION PUMP…………………………………………………………………614
20. GLOW PLUG………………………………………………………………………….614
21. NOZZLE HOLDER………………………………………………………………………615
22. FUEL FILTER,INJECTION TUBE…………………………………………………………..615
23. OIL FILTER,LEVEL GAUGE………………………………………………………………615
24. WATER PUMP…………………………………………………………………………615
25. STARTING MOTOR……………………………………………………………………..615
26. ALTERNATOR…………………………………………………………………………616
27. FAN,FAN PULLEY……………………………………………………………………..616
GENERAL DISASSEMBLY AND ASSEMBLY (4D95S-1)……………………………………………………….617
GENERAL DISASSEMBLY (4D95S-1)……………………………………………………………….618
1. SETTING IN UNIT REPAIR STAND………………………………………………………….618
2. FAN………………………………………………………………………………..618
3. ALTERNATOR………………………………………………………………………….618
4. FAN PULLEY………………………………………………………………………….618
5. STARTING MOTOR………………………………………………………………………619
6. FUEL INJECTION PIPE………………………………………………………………….619
7. FUEL INJECTION PUMP………………………………………………………………….619
8. INTAKE MANIFOLD……………………………………………………………………..619
9. WATER PUMP………………………………………………………………………….620
10. GLOW WIRE,GLOW PLUG…………………………………………………………………620
11. NOZZLE HOLDER………………………………………………………………………620
12. CYLINDER HEAD COVER…………………………………………………………………620
13. ROCKER ARM ASSEMBLY…………………………………………………………………620
14. PUSH RODS………………………………………………………………………….621
15. CYLINDER HEAD ASSEMBLY………………………………………………………………621
16. PTO SHAFT………………………………………………………………………….622
17. OIL PAN……………………………………………………………………………622
18. OIL SUCTION PIPE……………………………………………………………………622
19. CRANKSHAFT PULLEY…………………………………………………………………..622
20. GEAR CASE COVER…………………………………………………………………….623
21. OIL PUMP…………………………………………………………………………..623
22. IDLER GEAR…………………………………………………………………………623
23. CAMSHAFT ASSEMBLY…………………………………………………………………..623
24. FLYWHEEL…………………………………………………………………………..624
25. FLYWHEEL HOUSING……………………………………………………………………624
26. PISTON,CONNECTING ROD ASSEMBLY……………………………………………………….624
27. MAIN CAP…………………………………………………………………………..626
28. CRANKSHAFT…………………………………………………………………………627
29. TAPPET…………………………………………………………………………….627
GENERAL ASSEMBLY (4D95S-1)………………………………………………………………….628
1. SETTING IN UNIT REPAIR STAND………………………………………………………….628
2. TAPPET……………………………………………………………………………..628
3. CRANKSHAFT………………………………………………………………………….628
4. MAIN CAP……………………………………………………………………………629
5. PISTON,CONNECTING ROD ASSEMBLY………………………………………………………..630
6. FLYWHEEL HOUSING…………………………………………………………………….633
7. FLYWHEEL……………………………………………………………………………634
8. CAMSHAFT ASSEMBLY……………………………………………………………………634
9. IDLER GEAR………………………………………………………………………….634
10. OIL PUMP…………………………………………………………………………..635
11. GEAR CASE COVER…………………………………………………………………….636
12. CRANKSHAFT PULLEY ………………………………………………………………….636
13. OIL SUCTION PIPE……………………………………………………………………636
14. OIL PAN……………………………………………………………………………637
15. PTO SHAFT………………………………………………………………………….637
16. CYLINDER HEAD ASSEMBLY………………………………………………………………637
17. PUSH RODS………………………………………………………………………….638
18. ROCKER ARM ASSEMBLY…………………………………………………………………639
19. ADJUSTING VALVE CLEARANCE……………………………………………………………639
20. CYLINDER HEAD COVER…………………………………………………………………640
21. NOZZLE HOLDER………………………………………………………………………640
22. GLOW WIRE,GLOW PLUG…………………………………………………………………640
23. WATER PUMP…………………………………………………………………………640
24. INTAKE MANIFOLD…………………………………………………………………….640
25. FUEL INJECTION PUMP…………………………………………………………………641
26. FUEL INJECTION PIPE…………………………………………………………………641
27. STARTING MOTOR……………………………………………………………………..641
28. FAN PULLEY ………………………………………………………………………..642
29. ALTERNATOR…………………………………………………………………………642
30. FAN……………………………………………………………………………….642
31. LOWERING ENGINE…………………………………………………………………….642
GENERAL DISASSEMBLY (4D95L SERIES)………………………………………………………………643
GENERAL ASSEMBLY (4D95L SERIES)…………………………………………………………………657
GENERAL DISASSEMBLY (6D95L SERIES)………………………………………………………………678
GENERAL ASSEMBLY (6D95L SERIES)…………………………………………………………………691
DISASSEMBLY AND ASSEMBLY OF AIR COMPRESSOR……………………………………………………….712
14 MAINTENANCE STANDARD……………………………………………………………………………719
TURBOCHARGER………………………………………………………………………………….720
CYLINDER HEAD…………………………………………………………………………………723
VALVE,VALVE GUIDE……………………………………………………………………………..728
ROCKER ARM SHAFT,PUSH ROD AND TAPPET…………………………………………………………….731
CYLINDER BLOCK………………………………………………………………………………..732
CRANKSHAFT……………………………………………………………………………………734
CAMSHAFT……………………………………………………………………………………..738
TIMING GEAR (HELICAL GEAR)……………………………………………………………………..744
FLYWHEEL AND FLYWHEEL HOUSING…………………………………………………………………..748
PISTON,PISTON RING AND PISTON PIN……………………………………………………………….749
CONNECTING ROD………………………………………………………………………………..758
OIL PUMP……………………………………………………………………………………..759
REGULATOR VALVE……………………………………………………………………………….761
WATER PUMP,THERMOSTAT………………………………………………………………………….762
FUEL SYSTEM…………………………………………………………………………………..765
15 REPAIR AND REPLACEMENT………………………………………………………………………….767
TABLE OF SPECIAL TOOLS…………………………………………………………………………768
GRINDING CYLINDER HEAD MOUNTING SURFACE………………………………………………………….769
REPLACING VALVE SEAT INSERT…………………………………………………………………….770
REPLACING VALVE GUIDE………………………………………………………………………….774
GRINDING VALVE………………………………………………………………………………..775
REPLACING CAM BUSHING………………………………………………………………………….776
REPLACING CRANKSHAFT GEAR………………………………………………………………………778
REPLACING CAM GEAR…………………………………………………………………………….778
REPLACING FLYWHEEL RING GEAR……………………………………………………………………779
PRESSURE TEST…………………………………………………………………………………780
CYLINDER LINER (SPECIAL RESTORATION PART)………………………………………………………..781
MACHINING DRAWING FOR CYLINDER BLOCK BORE………………………………………………………..782
ADDITIONAL MACHINING OF CAM JOURNAL……………………………………………………………..783
GRINDING CRANKSHAFT……………………………………………………………………………784