Complete service repair manual with Electrical Wiring Diagrams for Komatsu 95 Series Diesel Engines, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

Komatsu 95 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.

SEBE61460114 - 95 Series Diesel Engine Shop Manual.pdf
SEBM018803 - 95-2 Series Diesel Engine Shop Manual.pdf
SEBM031001 - 95-3 Series Diesel Engines Shop Manual.pdf
SEN04408-00 - 95 Series Diesel Engine Shop Manual.pdf

PRODUCT DETAILS:
Total Pages: 1,422 pages
File Format: PDF
Language: English

MAIN SECTIONS
01 GENERAL ....... 01-1
11 STRUCTURE AND FUNCTION .... 11-1
12 TESTING AND ADJUSTING ..... 12-1
13 DISASSEMBLY AND ASSEMBLY .... 13-1
14 MAINTENANCE STANDARD ..... 14-1
15 REPAIR AND REPLACEMENT OF PARTS ... 15-1

Complete service repair manual with Electrical Wiring Diagrams for Komatsu 95 Series Diesel Engines, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

Komatsu 95 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.

SEBE61460114 - 95 Series Diesel Engine Shop Manual.pdf
SEBM018803 - 95-2 Series Diesel Engine Shop Manual.pdf
SEBM031001 - 95-3 Series Diesel Engines Shop Manual.pdf
SEN04408-00 - 95 Series Diesel Engine Shop Manual.pdf

PRODUCT DETAILS:
Total Pages: 1,422 pages
File Format: PDF
Language: English

MAIN SECTIONS
01 GENERAL ....... 01-1
11 STRUCTURE AND FUNCTION .... 11-1
12 TESTING AND ADJUSTING ..... 12-1
13 DISASSEMBLY AND ASSEMBLY .... 13-1
14 MAINTENANCE STANDARD ..... 14-1
15 REPAIR AND REPLACEMENT OF PARTS ... 15-1

SEBE61460114 - 95 Series Diesel Engine Shop Manual................2
  CONTENTS................3
  01 GENERAL ................28
    GENERAL VIEW ................29
    SPECIFICATIONS ................31
    GENERAL ASSEMBLY DRAWING ................53
    ENGINE PERFORMANCE CURVE ................95
    WEIGHT TABLE................155
  11 STRUCTURE AND FUNCTION ................158
    GENERAL STRUCTURE ................159
    INTAKE AND EXHAUST SYSTEM ................170
      INTAKE AND EXHAUST SYSTEM................170
      FTG AIR CLEANER................186
      TURBOCHARGER................190
      AFTER-COOLER................197
    ENGINE BODY................199
      CYLINDER HEAD................199
      VALVE SYSTEM................219
      CYLINDER BLOCK................227
      CYLINDER LINER................233
      MAIN CIRCULATION SYSTEM................235
      TIMING GEAR................253
      FLYWHEEL AND FLYWHEEL HOUSING................259
    LUBRICATION SYSTEM................264
      LUBRICATION SYSTEM CHART................264
      OIL PUMP ................270
      OIL FILTER ................271
      OIL COOLER ................273
    FUEL SYSTEM ................275
      FUEL SYSTEM CHART ................275
      FUEL INJECTION PUMP ................287
      GOVERNOR................317
      FEED PUMP................321
      FUEL INJECTION NOZZLE ................323
      FUEL CUT SOLENOID ................326
      ENGINE STOP MOTOR ................329
      FUEL FILTER ................334
      WATER SEPARATOR ................335
    COOLING SYSTEM ................336
      COOLING SYSTEM CHART ................336
      WATER PUMP ................339
      CORROSION RESISTOR (OPTION) ................342
      THERMOSTAT  AND FAN DRIVE ................343
    ELECTRICAL SYSTEM................353
      ALTERNATOR................353
      STARTING MOTOR ................362
      ELECTRICAL INTAKE AIR HEATER ................368
    ACCESSORY................373
      AIR COMPRESSOR................373
  12 TESTING AND ADJUSTING................376
    INTAKE AND EXHAUST SYSTEM................377
      ADJUSTING VALVE CLEARANCE................377
      MEASURING EXHAUST GAS COLOR................379
    ENGINE BODY................380
      MEASURING COMPRESSION PRESSURE................380
      MEASURING BLOW-BY PRESSURE................381
      ADJUSTING ENGINE SPEED SENSOR................382
    FUEL SYSTEM................383
      CHECKING AND ADJUSTING FUEL INJECTION TIMING................383
      ADJUSTING GOVERNOR................393
      TESTING AND ADJUSTING FUEL CUT SOLENOID................396
      PROCEDURE FOR ADJUSTING ENGINE STOP MOTOR CABLE................401
      ADJUSTING FUEL INJECTION PRESSURE................403
    LUBRICATION SYSTEM................406
      MEASURING OIL PRESSURE................406
      MEASURING OIL TEMPERATURE................407
    COOLING SYSTEM................408
      MEASURING WATER TEMPERATURE................408
      TESTING AND ADJUSTING FAN BELT TENSION................409
    FUEL INJECTION PUMP CALIBRATION DATA................410
    PERFORMANCE TEST................529
      RUN-IN STANDARD................529
      PERFORMANCE TEST CRITERIA................538
      TESTING AND ADJUSTING TOOL LIST................559
      TESTING AND ADJUSTING DATA................560
    TROUBLESHOOTING................583
      METHOD OF USING TROUBLESHOOTING TABLE................584
      POINTS TO REMEMBER WHEN TROUBLESHOOTING................588
      S-1 Starting performance is poor (Starting always takes time) ................589
      S-2 Engine does not start................590
        (1) Engine does not turn................590
        (2) Engine turns but no exhaust gas comes out (Fuel is not being injected)................591
        (3) Exhaust gas comes out but engine does not start (Fuel is being injected)................592
      S-3 Engine does not pick up smoothly (Follow-up is poor) ................593
      S-4 Engine stops during operations ................594
      S-5 Engine does not rotate smoothly ................595
      S-6 Engine lacks output (no power) ................596
      S-7 Exhaust gas is black (incomplete combustion) ................597
      S-8 Oil consumption is excessive (or exhaust gas is blue)................598
      S-9 Oil becomes contaminated quickly ................599
      S-10 Fuel consumption is excessive ................600
      S-11 Oil is in cooling water, or water spurts back, or water level ................601
      S-12 Oil pressure lamp lights up (drop in oil pressure) ................602
      S-13 Oil level rises................603
      S-14 Water temperature becomes too high (overheating) ................604
      S-15 Abnormal noise is made................605
      S-16 Vibration is excessive................606
      S-17 Diagnosis of electronical governor by diagnosis display (electronical governor made by ZEXEL)................607
  13 DISASSEMBLY AND ASSEMBLY................623
    3D95S-W-1................624
      GENERAL DISASSEMBLY................625
      GENERAL ASSEMBLY ................632
    4D95S-1................645
      GENERAL DISASSEMBLY................646
      GENERAL ASSEMBLY ................656
    4D95L SERIES................672
      GENERAL DISASSEMBLY................672
      GENERAL ASSEMBLY................686
    6D95L SERIES................708
      GENERAL DISASSEMBLY................708
      GENERAL ASSEMBLY................722
    DISASSEMBLY AND ASSEMBLY OF AIR COMPRESSOR................746
  14 MAINTENANCE STANDARD ................753
    TURBOCHARGER ................754
    CYLINDER HEAD ................757
    VALVE, VALVE GUIDE................762
    ROCKER ARM SHAFT, PUSH ROD AND TAPPET................765
    CYLINDER BLOCK ................766
    CRANKSHAFT ................768
    CAMSHAFT ................772
    TIMING GEAR (HELICAL GEAR) ................778
    FLYWHEEL AND FLYWHEEL HOUSING ................783
    PISTON, PISTON RING AND PISTON PIN................784
    CONNECTING ROD ................793
    OIL PUMP ................794
    REGULATOR VALVE ................796
    WATER PUMP, THERMOSTAT ................797
    FUEL SYSTEM ................800
  15 REPAIR AND REPLACEMENT ................803
    CYLINDER HEAD SECTION................805
      GRINDING CYLINDER HEAD  MOUNTING  SURFACE ................805
      REPLACING VALVE SEAT INSERT................806
      REPLACING VALVE GUIDE ................810
      GRINDING VALVE ................811
    CYLINDER BLOCK SECTION................812
      REPLACING CAM BUSHING ................812
      REPLACING GEARS................814
      PROCEDURE FOR PRESSURE TEST ................816
      CYLINDER LINER (SPECIAL RESTORATION PART) ................817
      MACHINING DRAWING FOR CYLINDER BLOCK BORE ................818
      ADDITIONAL MACHINING OF CAM JOURNAL ................819
      GRINDING CRANKSHAFT ................820
SEBM018803 - 95-2 Series Diesel Engine Shop Manual................822
  COVER................822
  CONTENTS................823
  SAFETY................826
    SAFETY NOTICE................826
  FOREWORD................828
    GENERAL................828
    HOW TO READ THE SHOP MANUAL................829
    HOISTING INSTRUCTIONS................830
    METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER................831
    COATING MATERIALS................833
    STANDARD TIGHTENING TORQUE................835
    ELECTRIC WIRE CODE................838
    CONVERSION TABLE................839
    UNITS................845
  01 GENERAL................846
    APPLICABLE MACHINE................847
    SPECIFICATIONS................848
    WEIGHT TABLE................850
    OVERALL DRAWING ................851
    ENGINE PERFORMANCE CURVE................854
  11 STRUCTURE AND FUNCTION................857
    GENERAL STRUCTURE................858
      GENERAL STRUCTURE................858
    INTAKE AND EXHAUST SYSTEM ................860
      INTAKE AND EXHAUST SYSTEM ................860
      AIR CLEANER................862
    ENGINE BODY................864
      CYLINDER HEAD................864
      CYLINDER BLOCK................866
      MAIN CIRCULATION SYSTEM................868
      TIMING GEAR................870
      VALVE SYSTEM ................872
      FLYWHEEL AND FLYWHEEL HOUSING................874
    LUBRICATION SYSTEM ................876
      LUBRICATION SYSTEM CHART................876
      OIL PUMP................877
      OIL FILTER ................878
      OIL FILTER MOUNT................879
    FUEL SYSTEM ................881
      FUEL SYSTEM CHART................881
      FUEL INJECTION PUMP................882
      FUEL INJECTION NOZZLE................884
      FUEL FILTER................885
      ENGINE CUT SOLENOID................886
    COOLING SYSTEM................887
      COOLING SYSTEM CHART................887
      WATER PUMP................888
      FAN DRIVE AND THERMOSTAT................889
    ELECTRICAL SYSTEM ................892
      STARTING AND CHARGING SYSTEM ELECTRICAL CIRCUIT DIAGRAM................892
      ALTERNATOR................893
      STARTING MOTOR................894
      ENGINE STARTING DEVICE................895
  12 TESTING AND ADJUSTING................896
    TESTING AND ADJUSTING................897
      ADJUSTING VALVLE CLEARANCE................897
      MEASURING COMPRESSION PRESSURE................899
      ADJUSTING FUEL INJECTION PRESSURE................900
      TESTING AND ADJUSTING FUEL INJECTION TIMING................901
      ADJUSTING FUEL CUT SOLENOID................905
    FUEL INJECTION PUMP CALIBRATION DATA................908
    PERFORMANCE TEST ................911
      RUN-IN STANDARD................911
      PERFORMANCE TEST CRITERIA ................912
    TROUBLESHOOTING................914
      METHOD OF USING TROUBLESHOOTING CHARTS................915
      POINTS TO REMEMBER WHEN TROUBLESHOOTING................919
      S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)................920
      S-2 ENGINE DOES NOT START................921
        (1) ENGINE DOES NOT TURN................921
        (2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED)................922
        (3) EXHAUST SMOKE COMES OUT, BUT ENGINE DOES NOT START (FUEL IS NOT BEING INJECTED)................923
      S-3 ENGINE DOES NOT PICK UP SMOOTHLY................924
      S-4 ENGINE STOPS DURING OPERATIONS................925
      S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)................926
      S-6 ENGINE LACK OUTPUT (NO POWER)................927
      S-7 EXHAUST GAS IS BLACK................928
      S-8 OIL CONSUMPTION IS EXCESSIVE, OR EXHAUST GAS IS BLUE................929
      S-9 OIL BECOMES CONTAMINATED QUICKLY................930
      S-10 FUEL CONSUMPTION IS EXCESSIVE................931
      S-11 OIL IS IN COOLING WATER ................932
      S-12 OIL PRESSURE CAUTION LAMP LIGHTS UPS (DROP IN OIL PRESSURE)................933
      S-13 OIL LEVEL RISES (WATER, FUEL IN OIL )................934
      S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)................935
      S-15 ABNORMAL NOISE IS MADE................936
      S-16 VIBRATION IS EXCESSIVE................937
    TESTING AND ADJUSTING TOOL LIST................938
    TESTING AND ADJUSTING DATA................939
  13 DISASSEMBLY AND ASSEMBLY................941
    SPECIAL TOOL LIST................942
    OVERALL DISASSEMBLY OF 4D95LC-2................943
      PREPARATORY WORK................944
      1. ALTERNATOR, FAN PULLEY................944
      2. STARTING MOTOR, ENGINE STOP SOLENOID, FUEL AND OIL FILTERS, DIPSTICK................945
      3. WATER PUMP................945
      4. FUEL INJECTION TUBE, GLOW PLUG................945
      5. INJECTION NOZZLE................945
      6. FUEL INJECTION PUMP................946
      7. INTAKE MANIFOLD................946
      8. EXHAUST MANIFOLD................946
      9. HEAD COVER................946
      10. ROCKER ARM................947
      11. PUSH ROD, CYLINDER HEAD MOUNTING BOLT................947
      12. CYLINDER HEAD COVER................947
      13. PTO SHAFT................948
      14. OIL PAN................949
      15. OIL SUCTION PIPE................949
      16. CRANKSHAFT PULLEY................949
      17. GEAR CASE COVER................949
      18. OIL PUMP, IDLER GEAR................950
      19. CAMSHAFT ASSEMBLY................950
      20. FLYWHEEL................950
      21. FLYWHEEL HOUSING................951
      22. PISTION, CONNECTING ROD ASSEMBLY................951
      23. MAIN CAP................953
      24. CRANKSHAFT................954
      25. TAPPET................954
      26.CYLINDER BLOCK ASSEMBLY................954
    OVERALL ASSEMBLY................955
      1. CYLINDER BLOCK ASSEMBLY................955
      2. TAPPET................955
      3. CRANKSHAFT................955
      4. MAIN CAP................956
      5. FLYWHEEL HOUSING................959
      6. FLYWHEEL................960
      7. CAMSHAFT ASSEMBLY................960
      8. OIL PUMP, IDLER GEAR................961
      9. GEAR CASE COVER................962
      10. CRANKSHAFT PULLEY................962
      11. OIL SUCTION PIPE................962
      12. OIL PAN................963
      13. PTO SHAFT................963
      14. FUEL INJECTION PUMP................963
      15. CYLINDER HEAD ASSEMBLY................964
      16. ADJUSTMENT OF VALVE CLEARANCE................966
      17. HEAD COVER................967
      18. EXHAUST MANIFOLD................967
      19. INTAKE MANIFOLD................967
      20. INJECTION NOZZLE................967
      21. FUEL INJECTION TUBE, GLOW PLUG................968
      22. WATER PUMP................968
      23. STARTING MOTOR. ENGINE STOP SOLENOID, FUEL AND OIL FILTERS, DIPSTICK................968
      24. ALTERNATOR, FAN PULLEY................969
      25. ENGINE ASSEMBLY................969
      26. FAN, EXHAUST PIPE, MUFFLER, ENGINE OIL TUBES, BLOCK, COVER................970
  14 MAINTENANCE STANDARD................971
    CYLINDER HEAD................972
    VALVE AND VALVE GUIDE................973
    ROCKER ARM SHAFT, PUSH ROD AND TAPPET................974
    CYLINDER BLOCK................975
    CYLINDER................976
    CRANKSHAFT................977
    CAMSHAFT................978
    TIMING GEAR................979
    PISTION, PISTON RING AND PISTION PIN................980
    CONNECTING ROD................981
    FLYWHEEL AND FLYWHEEL HOUSING................982
    OIL PUMP................983
    REGULATOR VALVE................984
    WATER PUMP AND THERMOSTAT................985
  15 REPAIR AND REPLACEMENT OF PARTS................986
    CYLINDER HEAD SECTION................987
      GRINDING CYLINDER HEAD MOUNTING SURFACE................987
      REPLACING VALVE GUIDE................988
      GRINDING VALVE................989
    CYLINDER BLOCK SECTION................990
      REPLACING CAMSHAFT BUSHING................990
      REPLACING CRANKSHAFT GEAR................992
      REPLACING CAM GEAR................993
      REPLACING FLYWHEEL RING GEAR................994
      PROCEDURE FOR PRESSURE TEST ................995
      CYLINDER LINER (SPECIAL RESTORATION PART)................996
      MACHINING DRAWING FOR CYLINDER BLOCK BORE................997
      ADDITIONAL MACHINING OF CAM JOURNAL................998
      GRINDING CRANKSHAFT................999
      REPLACING CONNECTING ROD SMALL END BUSHING................1000
SEBM031001 - 95-3 Series Diesel Engines Shop Manual................1002
  SAFETY ................1006
    SAFETY NOTICE ................1006
  FOREWORD ................1008
    GENERAL ................1008
    STANDARD TIGHTENING TORQUE ................1015
    CONVERSION TABLE ................1019
  SPECIFICATIONS ................1031
  OVERALL DRAWING ................1037
  GENERAL STRUCTURE ................1047
  INTAKE AND EXHAUST SYSTEM ................1049
  AIR CLEANER ................1053
  CYLINDER ................1066
  MAIN CIRCULATION SYSTEM ................1067
  CRANKSHAFT ................1071
  CONNECTING ROD ................1075
  TIMING GEAR ................1081
  CAMSHAFT ................1087
  ROCKER ARM SHAFT, PUSH ROD AND TAPPET ................1088
  OIL PUMP ................1091
  OIL FILTER ................1098
  FUEL SYSTEM CHART ................1100
  FUEL INJECTION PUMP ................1103
  COOLING SYSTEM CHART ................1114
  WATER PUMP ................1115
  STARTING AND CHARGING SYSTEM ELECTRICAL CIRCUIT DIAGRAM ................1121
  ADJUSTING VALVE CLEARANCE ................1129
  MEASURING COMPRESSION PRESSURE ................1131
  ADJUSTING FUEL INJECTION PRESSURE ( CRACKING PRESSURE) ................1132
  PERFORMANCE TEST ................1145
  METHOD OF USING TROUBLESHOOTING CHARTS ................1151
  POINTS TO REMEMBER WHEN TROUBLESHOOTING ................1155
  TESTING AND ADJUSTING TOOL LIST ................1174
  SPECIAL TOOL LIST ................1179
  OVERALL DISASSEMBLY, ASSEMBLY ................1180
  DISASSEMBLY ................1181
  ASSEMBLY ................1193
  GRINDING CYLINDER HEAD MOUNTING SURFACE ................1211
  REPLACING VALVE GUIDE ................1212
  GRINDING VALVE ................1213
  REPLACING CAMSHAFT BUSHING ................1214
  REPLACING CRANKSHAFT GEAR ................1216
  REPLACING CAM GEAR ................1217
  REPLACING FLYWHEEL RING GEAR ................1218
  PROCEDURE FOR PRESSURE TEST ................1219
  CYLINDER LINER ( SPECIAL RESTORATION PART) ................1220
  MACHINING DRAWING FOR CYLINDER BLOCK BORE ................1221
  GRINDING CRANKSHAFT ................1223
SEN04408-00 - 95 Series Diesel Engine Shop Manual................1226
  SEN04408-00 WA65-6, WA70-6, WA80-6................1226
  CONTENTS................1227
  SAFETY................1227
  FOREWORD................1229
  01 GENERAL................1248
    General................1249
    General view................1251
    4D95LWE-5................1251
    S4D95LWE-5................1253
    Specifications................1255
    General assembly drawing................1257
    4D95LWE-5 LEFT SIDE VIEW (WA65HH-6)................1257
    4D95LWE-5 RIGHT SIDE VIEW (WA65HH-6)................1258
    4D95LWE-5 FRONT VIEW (WA65HH-6)................1259
    4D95LWE-5 REAR VIEW (WA65HH-6)................1260
    S4D95LWE-5 LEFT SIDE VIEW (WA80HH-6)................1261
    S4D95LWE-5 RIGHT SIDE VIEW (WA80HH-6)................1262
    S4D95LWE-5 FRONT VIEW (WA80HH-6)................1263
    S4D95LWE-5 REAR VIEW (WA80HH-6)................1264
    DIMENSION TABLE................1265
    Engine performance curve................1266
    4D95LWE-5 [Applicable machine: WA65-HH-6]................1266
    4D95LWE-5 [Applicable machine: WA70-HH-6]................1267
    4D95LWE-5 [Applicable machine: WA80-HH-6]................1268
    Weight table................1269
  11 STRUCTURE AND FUNCTION................1270
    General structure................1271
    EXHAUST SYSTEM................1275
      Turbocharger................1275
      TD04L................1275
        Outline of waste gate valve................1276
    ENGINE BODY................1277
      Cylinder head................1277
        4D95LWE-5................1277
        Cylinder head................1278
        Head cover................1278
        S4D95LWE-5................1279
        Cylinder head................1280
        Head cover................1280
      Cylinder block................1281
      Main moving parts................1283
      Timing gear................1285
      WITHOUT FRONT PTO TYPE (HELICAL GEAR)................1285
        Front oil seal................1286
      Valve system................1287
      Flywheel and flywheel housing................1289
      WITHOUT REAR PTO TYPE................1289
    LUBRICATION SYSTEM................1291
      Lubrication system chart................1291
      Oil pump................1292
        Specifications................1292
        Oil pump................1292
        Regulator valve................1292
      Oil filter................1293
        Relief valve................1293
    FUEL SYSTEM................1294
      Fuel system chart................1294
      Fuel injection pump................1295
      Fuel injection nozzle................1297
      For direct fuel injection type................1297
      For swirl chamber type................1297
        Fuel injection nozzle................1297
    COOLING STSTEM................1298
      Cooling system chart................1298
      Thermostat and fan drive................1299
      THERMOSTAT (WITHOUT JIGGLE VALVE)................1301
    ELECTRICAL SYSTEM................1302
      Starting and charging system electrical circuit diagram................1302
      Alternator................1303
      ALTERNATOR WITH BUILT-IN REGULATOR (Open type, 90A)................1303
      Starting motor................1305
        For 2.2 kW................1305
      Engine starting device................1306
      GLOW PLUG (METAL 2-WIRE TYPE GLOW PLUG)................1306
        1. Connector (round 8-pin), (Short 8-pin)................1307
        2. Lead wire................1307
        3. Case................1307
        4. Bracket................1307
        5. Label................1307
        1. Water temperature sensor................1307
        1. Glow relay................1307
        2. Lead wire................1307
        3. Connector (round 2-in)................1307
  12 TESTING AND ADJUSTING................1308
    Performance test................1309
    Run-in standard................1309
    Performance test criteria................1311
    Testing and adjusting data................1313
    Testing and adjusting tools list................1314
    Intake and exhaust system................1315
    Adjusting valve clearance................1315
    Engine body................1317
    Measuring compression pressure................1317
      Measurement procedure................1317
    Fuel system................1318
    Adjusting fuel injection pressure (Cracking pressure)................1318
    Shim data for adjusting injection pressure................1319
    Testing and adjusting fuel injection timing................1320
    Table of injection pumps using plunger with stepped lead................1325
    Adjusting fuel injection rate................1326
    Governor adjustment standard................1327
    Troubleshooting................1330
    Method of using troubleshooting charts................1331
    Points on troubleshooting................1335
    S-1 Starting performance is poor (Starting always takes time)................1336
    S-2 Engine does not start................1337
      1) Engine does not turn................1337
      2) Engine turns but no exhaust gas comes out (Fuel is not being injected)................1338
      3) Exhaust gas comes out but engine does not start (Fuel is being injected)................1339
    S-3 Engine does not pick up smoothly (Follow-up is poor)................1340
    S-4 Engine stops during operations................1341
    S-5 Engine does not rotate smoothly................1342
    S-6 Engine lacks output (no power)................1343
    S-7 Exhaust gas is black (incomplete combustion)................1344
    S-8 Oil consumption is excessive (or exhaust gas is blue)................1345
    S-9 Oil becomes contaminated quickly................1346
    S-10 Fuel consumption is excessive................1347
    S-11 Oil is in coolant, or coolant spurts back, or coolant level goes down................1348
    S-12 Oil pressure lamp lights up (drop in oil pressure)................1349
    S-13 Oil level rises................1350
    S-14 Coolant temperature becomes too high (overheating)................1351
    S-15 Abnormal noise is made................1352
    S-16 Vibration is excessive................1353
  13 DISASSEMLY AND ASSEMBLY................1354
    General disassembly................1355
      Special tools................1355
    General assembly................1367
      Special tools................1367
  14 MAINTENANCE STANDARD................1386
    Turbocharger................1387
    Cylinder head................1389
    Valve, valve guide................1391
    Rocker arm shaft, push rod and tappet................1392
    Cylinder block................1393
    Cylinder................1395
    Crankshaft................1396
    Camshaft................1397
    Timing gear (Helical gear)................1399
    Flywheel and flywheel housing................1400
    Piston, piston ring and piston pin................1401
    Connecting rod................1403
    Regulator valve................1405
    Water pump and thermostat................1406
  15 REPAIR AND REPLACEMENT OF PARTS................1408
    Grinding cylinder head mounting surface................1409
    Replacing valve guide................1410
      Special tools................1410
    Grinding valve................1411
      Special tool................1411
    Replacing camshaft bushing................1412
      Special tools................1412
    Replacing crankshaft gear................1414
    Testing and adjusting fuel injection timing................1415
    Replacing flywheel ring gear................1416
    Procedure for pressure test................1417
      Special tools................1417
    Cylinder liner................1418
    (special restoration part)................1418
      Cylinder liner................1418
    Machining drawing for cylinder block bore................1419
    Additional machining of cam journal................1420
    Grinding crankshaft................1421
      Applicable crankshaft................1421
    Replacing connecting rod small end bushing................1422
      Special tools................1422

Komatsu 95 Series Diesel Engine Repair Service Manuals

Complete service repair manual with Electrical Wiring Diagrams for Komatsu 95 Series Diesel Engines, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

Komatsu 95 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.

SEBE61460114 - 95 Series Diesel Engine Shop Manual.pdf
SEBM018803 - 95-2 Series Diesel Engine Shop Manual.pdf
SEBM031001 - 95-3 Series Diesel Engines Shop Manual.pdf
SEN04408-00 - 95 Series Diesel Engine Shop Manual.pdf

PRODUCT DETAILS:
Total Pages: 1,422 pages
File Format: PDF
Language: English

MAIN SECTIONS
01 GENERAL ....... 01-1
11 STRUCTURE AND FUNCTION .... 11-1
12 TESTING AND ADJUSTING ..... 12-1
13 DISASSEMBLY AND ASSEMBLY .... 13-1
14 MAINTENANCE STANDARD ..... 14-1
15 REPAIR AND REPLACEMENT OF PARTS ... 15-1

SEBE61460114 - 95 Series Diesel Engine Shop Manual................2
  CONTENTS................3
  01 GENERAL ................28
    GENERAL VIEW ................29
    SPECIFICATIONS ................31
    GENERAL ASSEMBLY DRAWING ................53
    ENGINE PERFORMANCE CURVE ................95
    WEIGHT TABLE................155
  11 STRUCTURE AND FUNCTION ................158
    GENERAL STRUCTURE ................159
    INTAKE AND EXHAUST SYSTEM ................170
      INTAKE AND EXHAUST SYSTEM................170
      FTG AIR CLEANER................186
      TURBOCHARGER................190
      AFTER-COOLER................197
    ENGINE BODY................199
      CYLINDER HEAD................199
      VALVE SYSTEM................219
      CYLINDER BLOCK................227
      CYLINDER LINER................233
      MAIN CIRCULATION SYSTEM................235
      TIMING GEAR................253
      FLYWHEEL AND FLYWHEEL HOUSING................259
    LUBRICATION SYSTEM................264
      LUBRICATION SYSTEM CHART................264
      OIL PUMP ................270
      OIL FILTER ................271
      OIL COOLER ................273
    FUEL SYSTEM ................275
      FUEL SYSTEM CHART ................275
      FUEL INJECTION PUMP ................287
      GOVERNOR................317
      FEED PUMP................321
      FUEL INJECTION NOZZLE ................323
      FUEL CUT SOLENOID ................326
      ENGINE STOP MOTOR ................329
      FUEL FILTER ................334
      WATER SEPARATOR ................335
    COOLING SYSTEM ................336
      COOLING SYSTEM CHART ................336
      WATER PUMP ................339
      CORROSION RESISTOR (OPTION) ................342
      THERMOSTAT  AND FAN DRIVE ................343
    ELECTRICAL SYSTEM................353
      ALTERNATOR................353
      STARTING MOTOR ................362
      ELECTRICAL INTAKE AIR HEATER ................368
    ACCESSORY................373
      AIR COMPRESSOR................373
  12 TESTING AND ADJUSTING................376
    INTAKE AND EXHAUST SYSTEM................377
      ADJUSTING VALVE CLEARANCE................377
      MEASURING EXHAUST GAS COLOR................379
    ENGINE BODY................380
      MEASURING COMPRESSION PRESSURE................380
      MEASURING BLOW-BY PRESSURE................381
      ADJUSTING ENGINE SPEED SENSOR................382
    FUEL SYSTEM................383
      CHECKING AND ADJUSTING FUEL INJECTION TIMING................383
      ADJUSTING GOVERNOR................393
      TESTING AND ADJUSTING FUEL CUT SOLENOID................396
      PROCEDURE FOR ADJUSTING ENGINE STOP MOTOR CABLE................401
      ADJUSTING FUEL INJECTION PRESSURE................403
    LUBRICATION SYSTEM................406
      MEASURING OIL PRESSURE................406
      MEASURING OIL TEMPERATURE................407
    COOLING SYSTEM................408
      MEASURING WATER TEMPERATURE................408
      TESTING AND ADJUSTING FAN BELT TENSION................409
    FUEL INJECTION PUMP CALIBRATION DATA................410
    PERFORMANCE TEST................529
      RUN-IN STANDARD................529
      PERFORMANCE TEST CRITERIA................538
      TESTING AND ADJUSTING TOOL LIST................559
      TESTING AND ADJUSTING DATA................560
    TROUBLESHOOTING................583
      METHOD OF USING TROUBLESHOOTING TABLE................584
      POINTS TO REMEMBER WHEN TROUBLESHOOTING................588
      S-1 Starting performance is poor (Starting always takes time) ................589
      S-2 Engine does not start................590
        (1) Engine does not turn................590
        (2) Engine turns but no exhaust gas comes out (Fuel is not being injected)................591
        (3) Exhaust gas comes out but engine does not start (Fuel is being injected)................592
      S-3 Engine does not pick up smoothly (Follow-up is poor) ................593
      S-4 Engine stops during operations ................594
      S-5 Engine does not rotate smoothly ................595
      S-6 Engine lacks output (no power) ................596
      S-7 Exhaust gas is black (incomplete combustion) ................597
      S-8 Oil consumption is excessive (or exhaust gas is blue)................598
      S-9 Oil becomes contaminated quickly ................599
      S-10 Fuel consumption is excessive ................600
      S-11 Oil is in cooling water, or water spurts back, or water level ................601
      S-12 Oil pressure lamp lights up (drop in oil pressure) ................602
      S-13 Oil level rises................603
      S-14 Water temperature becomes too high (overheating) ................604
      S-15 Abnormal noise is made................605
      S-16 Vibration is excessive................606
      S-17 Diagnosis of electronical governor by diagnosis display (electronical governor made by ZEXEL)................607
  13 DISASSEMBLY AND ASSEMBLY................623
    3D95S-W-1................624
      GENERAL DISASSEMBLY................625
      GENERAL ASSEMBLY ................632
    4D95S-1................645
      GENERAL DISASSEMBLY................646
      GENERAL ASSEMBLY ................656
    4D95L SERIES................672
      GENERAL DISASSEMBLY................672
      GENERAL ASSEMBLY................686
    6D95L SERIES................708
      GENERAL DISASSEMBLY................708
      GENERAL ASSEMBLY................722
    DISASSEMBLY AND ASSEMBLY OF AIR COMPRESSOR................746
  14 MAINTENANCE STANDARD ................753
    TURBOCHARGER ................754
    CYLINDER HEAD ................757
    VALVE, VALVE GUIDE................762
    ROCKER ARM SHAFT, PUSH ROD AND TAPPET................765
    CYLINDER BLOCK ................766
    CRANKSHAFT ................768
    CAMSHAFT ................772
    TIMING GEAR (HELICAL GEAR) ................778
    FLYWHEEL AND FLYWHEEL HOUSING ................783
    PISTON, PISTON RING AND PISTON PIN................784
    CONNECTING ROD ................793
    OIL PUMP ................794
    REGULATOR VALVE ................796
    WATER PUMP, THERMOSTAT ................797
    FUEL SYSTEM ................800
  15 REPAIR AND REPLACEMENT ................803
    CYLINDER HEAD SECTION................805
      GRINDING CYLINDER HEAD  MOUNTING  SURFACE ................805
      REPLACING VALVE SEAT INSERT................806
      REPLACING VALVE GUIDE ................810
      GRINDING VALVE ................811
    CYLINDER BLOCK SECTION................812
      REPLACING CAM BUSHING ................812
      REPLACING GEARS................814
      PROCEDURE FOR PRESSURE TEST ................816
      CYLINDER LINER (SPECIAL RESTORATION PART) ................817
      MACHINING DRAWING FOR CYLINDER BLOCK BORE ................818
      ADDITIONAL MACHINING OF CAM JOURNAL ................819
      GRINDING CRANKSHAFT ................820
SEBM018803 - 95-2 Series Diesel Engine Shop Manual................822
  COVER................822
  CONTENTS................823
  SAFETY................826
    SAFETY NOTICE................826
  FOREWORD................828
    GENERAL................828
    HOW TO READ THE SHOP MANUAL................829
    HOISTING INSTRUCTIONS................830
    METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER................831
    COATING MATERIALS................833
    STANDARD TIGHTENING TORQUE................835
    ELECTRIC WIRE CODE................838
    CONVERSION TABLE................839
    UNITS................845
  01 GENERAL................846
    APPLICABLE MACHINE................847
    SPECIFICATIONS................848
    WEIGHT TABLE................850
    OVERALL DRAWING ................851
    ENGINE PERFORMANCE CURVE................854
  11 STRUCTURE AND FUNCTION................857
    GENERAL STRUCTURE................858
      GENERAL STRUCTURE................858
    INTAKE AND EXHAUST SYSTEM ................860
      INTAKE AND EXHAUST SYSTEM ................860
      AIR CLEANER................862
    ENGINE BODY................864
      CYLINDER HEAD................864
      CYLINDER BLOCK................866
      MAIN CIRCULATION SYSTEM................868
      TIMING GEAR................870
      VALVE SYSTEM ................872
      FLYWHEEL AND FLYWHEEL HOUSING................874
    LUBRICATION SYSTEM ................876
      LUBRICATION SYSTEM CHART................876
      OIL PUMP................877
      OIL FILTER ................878
      OIL FILTER MOUNT................879
    FUEL SYSTEM ................881
      FUEL SYSTEM CHART................881
      FUEL INJECTION PUMP................882
      FUEL INJECTION NOZZLE................884
      FUEL FILTER................885
      ENGINE CUT SOLENOID................886
    COOLING SYSTEM................887
      COOLING SYSTEM CHART................887
      WATER PUMP................888
      FAN DRIVE AND THERMOSTAT................889
    ELECTRICAL SYSTEM ................892
      STARTING AND CHARGING SYSTEM ELECTRICAL CIRCUIT DIAGRAM................892
      ALTERNATOR................893
      STARTING MOTOR................894
      ENGINE STARTING DEVICE................895
  12 TESTING AND ADJUSTING................896
    TESTING AND ADJUSTING................897
      ADJUSTING VALVLE CLEARANCE................897
      MEASURING COMPRESSION PRESSURE................899
      ADJUSTING FUEL INJECTION PRESSURE................900
      TESTING AND ADJUSTING FUEL INJECTION TIMING................901
      ADJUSTING FUEL CUT SOLENOID................905
    FUEL INJECTION PUMP CALIBRATION DATA................908
    PERFORMANCE TEST ................911
      RUN-IN STANDARD................911
      PERFORMANCE TEST CRITERIA ................912
    TROUBLESHOOTING................914
      METHOD OF USING TROUBLESHOOTING CHARTS................915
      POINTS TO REMEMBER WHEN TROUBLESHOOTING................919
      S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)................920
      S-2 ENGINE DOES NOT START................921
        (1) ENGINE DOES NOT TURN................921
        (2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED)................922
        (3) EXHAUST SMOKE COMES OUT, BUT ENGINE DOES NOT START (FUEL IS NOT BEING INJECTED)................923
      S-3 ENGINE DOES NOT PICK UP SMOOTHLY................924
      S-4 ENGINE STOPS DURING OPERATIONS................925
      S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)................926
      S-6 ENGINE LACK OUTPUT (NO POWER)................927
      S-7 EXHAUST GAS IS BLACK................928
      S-8 OIL CONSUMPTION IS EXCESSIVE, OR EXHAUST GAS IS BLUE................929
      S-9 OIL BECOMES CONTAMINATED QUICKLY................930
      S-10 FUEL CONSUMPTION IS EXCESSIVE................931
      S-11 OIL IS IN COOLING WATER ................932
      S-12 OIL PRESSURE CAUTION LAMP LIGHTS UPS (DROP IN OIL PRESSURE)................933
      S-13 OIL LEVEL RISES (WATER, FUEL IN OIL )................934
      S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)................935
      S-15 ABNORMAL NOISE IS MADE................936
      S-16 VIBRATION IS EXCESSIVE................937
    TESTING AND ADJUSTING TOOL LIST................938
    TESTING AND ADJUSTING DATA................939
  13 DISASSEMBLY AND ASSEMBLY................941
    SPECIAL TOOL LIST................942
    OVERALL DISASSEMBLY OF 4D95LC-2................943
      PREPARATORY WORK................944
      1. ALTERNATOR, FAN PULLEY................944
      2. STARTING MOTOR, ENGINE STOP SOLENOID, FUEL AND OIL FILTERS, DIPSTICK................945
      3. WATER PUMP................945
      4. FUEL INJECTION TUBE, GLOW PLUG................945
      5. INJECTION NOZZLE................945
      6. FUEL INJECTION PUMP................946
      7. INTAKE MANIFOLD................946
      8. EXHAUST MANIFOLD................946
      9. HEAD COVER................946
      10. ROCKER ARM................947
      11. PUSH ROD, CYLINDER HEAD MOUNTING BOLT................947
      12. CYLINDER HEAD COVER................947
      13. PTO SHAFT................948
      14. OIL PAN................949
      15. OIL SUCTION PIPE................949
      16. CRANKSHAFT PULLEY................949
      17. GEAR CASE COVER................949
      18. OIL PUMP, IDLER GEAR................950
      19. CAMSHAFT ASSEMBLY................950
      20. FLYWHEEL................950
      21. FLYWHEEL HOUSING................951
      22. PISTION, CONNECTING ROD ASSEMBLY................951
      23. MAIN CAP................953
      24. CRANKSHAFT................954
      25. TAPPET................954
      26.CYLINDER BLOCK ASSEMBLY................954
    OVERALL ASSEMBLY................955
      1. CYLINDER BLOCK ASSEMBLY................955
      2. TAPPET................955
      3. CRANKSHAFT................955
      4. MAIN CAP................956
      5. FLYWHEEL HOUSING................959
      6. FLYWHEEL................960
      7. CAMSHAFT ASSEMBLY................960
      8. OIL PUMP, IDLER GEAR................961
      9. GEAR CASE COVER................962
      10. CRANKSHAFT PULLEY................962
      11. OIL SUCTION PIPE................962
      12. OIL PAN................963
      13. PTO SHAFT................963
      14. FUEL INJECTION PUMP................963
      15. CYLINDER HEAD ASSEMBLY................964
      16. ADJUSTMENT OF VALVE CLEARANCE................966
      17. HEAD COVER................967
      18. EXHAUST MANIFOLD................967
      19. INTAKE MANIFOLD................967
      20. INJECTION NOZZLE................967
      21. FUEL INJECTION TUBE, GLOW PLUG................968
      22. WATER PUMP................968
      23. STARTING MOTOR. ENGINE STOP SOLENOID, FUEL AND OIL FILTERS, DIPSTICK................968
      24. ALTERNATOR, FAN PULLEY................969
      25. ENGINE ASSEMBLY................969
      26. FAN, EXHAUST PIPE, MUFFLER, ENGINE OIL TUBES, BLOCK, COVER................970
  14 MAINTENANCE STANDARD................971
    CYLINDER HEAD................972
    VALVE AND VALVE GUIDE................973
    ROCKER ARM SHAFT, PUSH ROD AND TAPPET................974
    CYLINDER BLOCK................975
    CYLINDER................976
    CRANKSHAFT................977
    CAMSHAFT................978
    TIMING GEAR................979
    PISTION, PISTON RING AND PISTION PIN................980
    CONNECTING ROD................981
    FLYWHEEL AND FLYWHEEL HOUSING................982
    OIL PUMP................983
    REGULATOR VALVE................984
    WATER PUMP AND THERMOSTAT................985
  15 REPAIR AND REPLACEMENT OF PARTS................986
    CYLINDER HEAD SECTION................987
      GRINDING CYLINDER HEAD MOUNTING SURFACE................987
      REPLACING VALVE GUIDE................988
      GRINDING VALVE................989
    CYLINDER BLOCK SECTION................990
      REPLACING CAMSHAFT BUSHING................990
      REPLACING CRANKSHAFT GEAR................992
      REPLACING CAM GEAR................993
      REPLACING FLYWHEEL RING GEAR................994
      PROCEDURE FOR PRESSURE TEST ................995
      CYLINDER LINER (SPECIAL RESTORATION PART)................996
      MACHINING DRAWING FOR CYLINDER BLOCK BORE................997
      ADDITIONAL MACHINING OF CAM JOURNAL................998
      GRINDING CRANKSHAFT................999
      REPLACING CONNECTING ROD SMALL END BUSHING................1000
SEBM031001 - 95-3 Series Diesel Engines Shop Manual................1002
  SAFETY ................1006
    SAFETY NOTICE ................1006
  FOREWORD ................1008
    GENERAL ................1008
    STANDARD TIGHTENING TORQUE ................1015
    CONVERSION TABLE ................1019
  SPECIFICATIONS ................1031
  OVERALL DRAWING ................1037
  GENERAL STRUCTURE ................1047
  INTAKE AND EXHAUST SYSTEM ................1049
  AIR CLEANER ................1053
  CYLINDER ................1066
  MAIN CIRCULATION SYSTEM ................1067
  CRANKSHAFT ................1071
  CONNECTING ROD ................1075
  TIMING GEAR ................1081
  CAMSHAFT ................1087
  ROCKER ARM SHAFT, PUSH ROD AND TAPPET ................1088
  OIL PUMP ................1091
  OIL FILTER ................1098
  FUEL SYSTEM CHART ................1100
  FUEL INJECTION PUMP ................1103
  COOLING SYSTEM CHART ................1114
  WATER PUMP ................1115
  STARTING AND CHARGING SYSTEM ELECTRICAL CIRCUIT DIAGRAM ................1121
  ADJUSTING VALVE CLEARANCE ................1129
  MEASURING COMPRESSION PRESSURE ................1131
  ADJUSTING FUEL INJECTION PRESSURE ( CRACKING PRESSURE) ................1132
  PERFORMANCE TEST ................1145
  METHOD OF USING TROUBLESHOOTING CHARTS ................1151
  POINTS TO REMEMBER WHEN TROUBLESHOOTING ................1155
  TESTING AND ADJUSTING TOOL LIST ................1174
  SPECIAL TOOL LIST ................1179
  OVERALL DISASSEMBLY, ASSEMBLY ................1180
  DISASSEMBLY ................1181
  ASSEMBLY ................1193
  GRINDING CYLINDER HEAD MOUNTING SURFACE ................1211
  REPLACING VALVE GUIDE ................1212
  GRINDING VALVE ................1213
  REPLACING CAMSHAFT BUSHING ................1214
  REPLACING CRANKSHAFT GEAR ................1216
  REPLACING CAM GEAR ................1217
  REPLACING FLYWHEEL RING GEAR ................1218
  PROCEDURE FOR PRESSURE TEST ................1219
  CYLINDER LINER ( SPECIAL RESTORATION PART) ................1220
  MACHINING DRAWING FOR CYLINDER BLOCK BORE ................1221
  GRINDING CRANKSHAFT ................1223
SEN04408-00 - 95 Series Diesel Engine Shop Manual................1226
  SEN04408-00 WA65-6, WA70-6, WA80-6................1226
  CONTENTS................1227
  SAFETY................1227
  FOREWORD................1229
  01 GENERAL................1248
    General................1249
    General view................1251
    4D95LWE-5................1251
    S4D95LWE-5................1253
    Specifications................1255
    General assembly drawing................1257
    4D95LWE-5 LEFT SIDE VIEW (WA65HH-6)................1257
    4D95LWE-5 RIGHT SIDE VIEW (WA65HH-6)................1258
    4D95LWE-5 FRONT VIEW (WA65HH-6)................1259
    4D95LWE-5 REAR VIEW (WA65HH-6)................1260
    S4D95LWE-5 LEFT SIDE VIEW (WA80HH-6)................1261
    S4D95LWE-5 RIGHT SIDE VIEW (WA80HH-6)................1262
    S4D95LWE-5 FRONT VIEW (WA80HH-6)................1263
    S4D95LWE-5 REAR VIEW (WA80HH-6)................1264
    DIMENSION TABLE................1265
    Engine performance curve................1266
    4D95LWE-5 [Applicable machine: WA65-HH-6]................1266
    4D95LWE-5 [Applicable machine: WA70-HH-6]................1267
    4D95LWE-5 [Applicable machine: WA80-HH-6]................1268
    Weight table................1269
  11 STRUCTURE AND FUNCTION................1270
    General structure................1271
    EXHAUST SYSTEM................1275
      Turbocharger................1275
      TD04L................1275
        Outline of waste gate valve................1276
    ENGINE BODY................1277
      Cylinder head................1277
        4D95LWE-5................1277
        Cylinder head................1278
        Head cover................1278
        S4D95LWE-5................1279
        Cylinder head................1280
        Head cover................1280
      Cylinder block................1281
      Main moving parts................1283
      Timing gear................1285
      WITHOUT FRONT PTO TYPE (HELICAL GEAR)................1285
        Front oil seal................1286
      Valve system................1287
      Flywheel and flywheel housing................1289
      WITHOUT REAR PTO TYPE................1289
    LUBRICATION SYSTEM................1291
      Lubrication system chart................1291
      Oil pump................1292
        Specifications................1292
        Oil pump................1292
        Regulator valve................1292
      Oil filter................1293
        Relief valve................1293
    FUEL SYSTEM................1294
      Fuel system chart................1294
      Fuel injection pump................1295
      Fuel injection nozzle................1297
      For direct fuel injection type................1297
      For swirl chamber type................1297
        Fuel injection nozzle................1297
    COOLING STSTEM................1298
      Cooling system chart................1298
      Thermostat and fan drive................1299
      THERMOSTAT (WITHOUT JIGGLE VALVE)................1301
    ELECTRICAL SYSTEM................1302
      Starting and charging system electrical circuit diagram................1302
      Alternator................1303
      ALTERNATOR WITH BUILT-IN REGULATOR (Open type, 90A)................1303
      Starting motor................1305
        For 2.2 kW................1305
      Engine starting device................1306
      GLOW PLUG (METAL 2-WIRE TYPE GLOW PLUG)................1306
        1. Connector (round 8-pin), (Short 8-pin)................1307
        2. Lead wire................1307
        3. Case................1307
        4. Bracket................1307
        5. Label................1307
        1. Water temperature sensor................1307
        1. Glow relay................1307
        2. Lead wire................1307
        3. Connector (round 2-in)................1307
  12 TESTING AND ADJUSTING................1308
    Performance test................1309
    Run-in standard................1309
    Performance test criteria................1311
    Testing and adjusting data................1313
    Testing and adjusting tools list................1314
    Intake and exhaust system................1315
    Adjusting valve clearance................1315
    Engine body................1317
    Measuring compression pressure................1317
      Measurement procedure................1317
    Fuel system................1318
    Adjusting fuel injection pressure (Cracking pressure)................1318
    Shim data for adjusting injection pressure................1319
    Testing and adjusting fuel injection timing................1320
    Table of injection pumps using plunger with stepped lead................1325
    Adjusting fuel injection rate................1326
    Governor adjustment standard................1327
    Troubleshooting................1330
    Method of using troubleshooting charts................1331
    Points on troubleshooting................1335
    S-1 Starting performance is poor (Starting always takes time)................1336
    S-2 Engine does not start................1337
      1) Engine does not turn................1337
      2) Engine turns but no exhaust gas comes out (Fuel is not being injected)................1338
      3) Exhaust gas comes out but engine does not start (Fuel is being injected)................1339
    S-3 Engine does not pick up smoothly (Follow-up is poor)................1340
    S-4 Engine stops during operations................1341
    S-5 Engine does not rotate smoothly................1342
    S-6 Engine lacks output (no power)................1343
    S-7 Exhaust gas is black (incomplete combustion)................1344
    S-8 Oil consumption is excessive (or exhaust gas is blue)................1345
    S-9 Oil becomes contaminated quickly................1346
    S-10 Fuel consumption is excessive................1347
    S-11 Oil is in coolant, or coolant spurts back, or coolant level goes down................1348
    S-12 Oil pressure lamp lights up (drop in oil pressure)................1349
    S-13 Oil level rises................1350
    S-14 Coolant temperature becomes too high (overheating)................1351
    S-15 Abnormal noise is made................1352
    S-16 Vibration is excessive................1353
  13 DISASSEMLY AND ASSEMBLY................1354
    General disassembly................1355
      Special tools................1355
    General assembly................1367
      Special tools................1367
  14 MAINTENANCE STANDARD................1386
    Turbocharger................1387
    Cylinder head................1389
    Valve, valve guide................1391
    Rocker arm shaft, push rod and tappet................1392
    Cylinder block................1393
    Cylinder................1395
    Crankshaft................1396
    Camshaft................1397
    Timing gear (Helical gear)................1399
    Flywheel and flywheel housing................1400
    Piston, piston ring and piston pin................1401
    Connecting rod................1403
    Regulator valve................1405
    Water pump and thermostat................1406
  15 REPAIR AND REPLACEMENT OF PARTS................1408
    Grinding cylinder head mounting surface................1409
    Replacing valve guide................1410
      Special tools................1410
    Grinding valve................1411
      Special tool................1411
    Replacing camshaft bushing................1412
      Special tools................1412
    Replacing crankshaft gear................1414
    Testing and adjusting fuel injection timing................1415
    Replacing flywheel ring gear................1416
    Procedure for pressure test................1417
      Special tools................1417
    Cylinder liner................1418
    (special restoration part)................1418
      Cylinder liner................1418
    Machining drawing for cylinder block bore................1419
    Additional machining of cam journal................1420
    Grinding crankshaft................1421
      Applicable crankshaft................1421
    Replacing connecting rod small end bushing................1422
      Special tools................1422

Komatsu 95 Series Diesel Engine Repair Service Manuals

Complete service repair manual with Electrical Wiring Diagrams for Komatsu 95 Series Diesel Engines, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

Komatsu 95 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.

SEBE61460114 - 95 Series Diesel Engine Shop Manual.pdf
SEBM018803 - 95-2 Series Diesel Engine Shop Manual.pdf
SEBM031001 - 95-3 Series Diesel Engines Shop Manual.pdf
SEN04408-00 - 95 Series Diesel Engine Shop Manual.pdf

PRODUCT DETAILS:
Total Pages: 1,422 pages
File Format: PDF
Language: English

MAIN SECTIONS
01 GENERAL ....... 01-1
11 STRUCTURE AND FUNCTION .... 11-1
12 TESTING AND ADJUSTING ..... 12-1
13 DISASSEMBLY AND ASSEMBLY .... 13-1
14 MAINTENANCE STANDARD ..... 14-1
15 REPAIR AND REPLACEMENT OF PARTS ... 15-1

SEBE61460114 - 95 Series Diesel Engine Shop Manual................2
  CONTENTS................3
  01 GENERAL ................28
    GENERAL VIEW ................29
    SPECIFICATIONS ................31
    GENERAL ASSEMBLY DRAWING ................53
    ENGINE PERFORMANCE CURVE ................95
    WEIGHT TABLE................155
  11 STRUCTURE AND FUNCTION ................158
    GENERAL STRUCTURE ................159
    INTAKE AND EXHAUST SYSTEM ................170
      INTAKE AND EXHAUST SYSTEM................170
      FTG AIR CLEANER................186
      TURBOCHARGER................190
      AFTER-COOLER................197
    ENGINE BODY................199
      CYLINDER HEAD................199
      VALVE SYSTEM................219
      CYLINDER BLOCK................227
      CYLINDER LINER................233
      MAIN CIRCULATION SYSTEM................235
      TIMING GEAR................253
      FLYWHEEL AND FLYWHEEL HOUSING................259
    LUBRICATION SYSTEM................264
      LUBRICATION SYSTEM CHART................264
      OIL PUMP ................270
      OIL FILTER ................271
      OIL COOLER ................273
    FUEL SYSTEM ................275
      FUEL SYSTEM CHART ................275
      FUEL INJECTION PUMP ................287
      GOVERNOR................317
      FEED PUMP................321
      FUEL INJECTION NOZZLE ................323
      FUEL CUT SOLENOID ................326
      ENGINE STOP MOTOR ................329
      FUEL FILTER ................334
      WATER SEPARATOR ................335
    COOLING SYSTEM ................336
      COOLING SYSTEM CHART ................336
      WATER PUMP ................339
      CORROSION RESISTOR (OPTION) ................342
      THERMOSTAT  AND FAN DRIVE ................343
    ELECTRICAL SYSTEM................353
      ALTERNATOR................353
      STARTING MOTOR ................362
      ELECTRICAL INTAKE AIR HEATER ................368
    ACCESSORY................373
      AIR COMPRESSOR................373
  12 TESTING AND ADJUSTING................376
    INTAKE AND EXHAUST SYSTEM................377
      ADJUSTING VALVE CLEARANCE................377
      MEASURING EXHAUST GAS COLOR................379
    ENGINE BODY................380
      MEASURING COMPRESSION PRESSURE................380
      MEASURING BLOW-BY PRESSURE................381
      ADJUSTING ENGINE SPEED SENSOR................382
    FUEL SYSTEM................383
      CHECKING AND ADJUSTING FUEL INJECTION TIMING................383
      ADJUSTING GOVERNOR................393
      TESTING AND ADJUSTING FUEL CUT SOLENOID................396
      PROCEDURE FOR ADJUSTING ENGINE STOP MOTOR CABLE................401
      ADJUSTING FUEL INJECTION PRESSURE................403
    LUBRICATION SYSTEM................406
      MEASURING OIL PRESSURE................406
      MEASURING OIL TEMPERATURE................407
    COOLING SYSTEM................408
      MEASURING WATER TEMPERATURE................408
      TESTING AND ADJUSTING FAN BELT TENSION................409
    FUEL INJECTION PUMP CALIBRATION DATA................410
    PERFORMANCE TEST................529
      RUN-IN STANDARD................529
      PERFORMANCE TEST CRITERIA................538
      TESTING AND ADJUSTING TOOL LIST................559
      TESTING AND ADJUSTING DATA................560
    TROUBLESHOOTING................583
      METHOD OF USING TROUBLESHOOTING TABLE................584
      POINTS TO REMEMBER WHEN TROUBLESHOOTING................588
      S-1 Starting performance is poor (Starting always takes time) ................589
      S-2 Engine does not start................590
        (1) Engine does not turn................590
        (2) Engine turns but no exhaust gas comes out (Fuel is not being injected)................591
        (3) Exhaust gas comes out but engine does not start (Fuel is being injected)................592
      S-3 Engine does not pick up smoothly (Follow-up is poor) ................593
      S-4 Engine stops during operations ................594
      S-5 Engine does not rotate smoothly ................595
      S-6 Engine lacks output (no power) ................596
      S-7 Exhaust gas is black (incomplete combustion) ................597
      S-8 Oil consumption is excessive (or exhaust gas is blue)................598
      S-9 Oil becomes contaminated quickly ................599
      S-10 Fuel consumption is excessive ................600
      S-11 Oil is in cooling water, or water spurts back, or water level ................601
      S-12 Oil pressure lamp lights up (drop in oil pressure) ................602
      S-13 Oil level rises................603
      S-14 Water temperature becomes too high (overheating) ................604
      S-15 Abnormal noise is made................605
      S-16 Vibration is excessive................606
      S-17 Diagnosis of electronical governor by diagnosis display (electronical governor made by ZEXEL)................607
  13 DISASSEMBLY AND ASSEMBLY................623
    3D95S-W-1................624
      GENERAL DISASSEMBLY................625
      GENERAL ASSEMBLY ................632
    4D95S-1................645
      GENERAL DISASSEMBLY................646
      GENERAL ASSEMBLY ................656
    4D95L SERIES................672
      GENERAL DISASSEMBLY................672
      GENERAL ASSEMBLY................686
    6D95L SERIES................708
      GENERAL DISASSEMBLY................708
      GENERAL ASSEMBLY................722
    DISASSEMBLY AND ASSEMBLY OF AIR COMPRESSOR................746
  14 MAINTENANCE STANDARD ................753
    TURBOCHARGER ................754
    CYLINDER HEAD ................757
    VALVE, VALVE GUIDE................762
    ROCKER ARM SHAFT, PUSH ROD AND TAPPET................765
    CYLINDER BLOCK ................766
    CRANKSHAFT ................768
    CAMSHAFT ................772
    TIMING GEAR (HELICAL GEAR) ................778
    FLYWHEEL AND FLYWHEEL HOUSING ................783
    PISTON, PISTON RING AND PISTON PIN................784
    CONNECTING ROD ................793
    OIL PUMP ................794
    REGULATOR VALVE ................796
    WATER PUMP, THERMOSTAT ................797
    FUEL SYSTEM ................800
  15 REPAIR AND REPLACEMENT ................803
    CYLINDER HEAD SECTION................805
      GRINDING CYLINDER HEAD  MOUNTING  SURFACE ................805
      REPLACING VALVE SEAT INSERT................806
      REPLACING VALVE GUIDE ................810
      GRINDING VALVE ................811
    CYLINDER BLOCK SECTION................812
      REPLACING CAM BUSHING ................812
      REPLACING GEARS................814
      PROCEDURE FOR PRESSURE TEST ................816
      CYLINDER LINER (SPECIAL RESTORATION PART) ................817
      MACHINING DRAWING FOR CYLINDER BLOCK BORE ................818
      ADDITIONAL MACHINING OF CAM JOURNAL ................819
      GRINDING CRANKSHAFT ................820
SEBM018803 - 95-2 Series Diesel Engine Shop Manual................822
  COVER................822
  CONTENTS................823
  SAFETY................826
    SAFETY NOTICE................826
  FOREWORD................828
    GENERAL................828
    HOW TO READ THE SHOP MANUAL................829
    HOISTING INSTRUCTIONS................830
    METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER................831
    COATING MATERIALS................833
    STANDARD TIGHTENING TORQUE................835
    ELECTRIC WIRE CODE................838
    CONVERSION TABLE................839
    UNITS................845
  01 GENERAL................846
    APPLICABLE MACHINE................847
    SPECIFICATIONS................848
    WEIGHT TABLE................850
    OVERALL DRAWING ................851
    ENGINE PERFORMANCE CURVE................854
  11 STRUCTURE AND FUNCTION................857
    GENERAL STRUCTURE................858
      GENERAL STRUCTURE................858
    INTAKE AND EXHAUST SYSTEM ................860
      INTAKE AND EXHAUST SYSTEM ................860
      AIR CLEANER................862
    ENGINE BODY................864
      CYLINDER HEAD................864
      CYLINDER BLOCK................866
      MAIN CIRCULATION SYSTEM................868
      TIMING GEAR................870
      VALVE SYSTEM ................872
      FLYWHEEL AND FLYWHEEL HOUSING................874
    LUBRICATION SYSTEM ................876
      LUBRICATION SYSTEM CHART................876
      OIL PUMP................877
      OIL FILTER ................878
      OIL FILTER MOUNT................879
    FUEL SYSTEM ................881
      FUEL SYSTEM CHART................881
      FUEL INJECTION PUMP................882
      FUEL INJECTION NOZZLE................884
      FUEL FILTER................885
      ENGINE CUT SOLENOID................886
    COOLING SYSTEM................887
      COOLING SYSTEM CHART................887
      WATER PUMP................888
      FAN DRIVE AND THERMOSTAT................889
    ELECTRICAL SYSTEM ................892
      STARTING AND CHARGING SYSTEM ELECTRICAL CIRCUIT DIAGRAM................892
      ALTERNATOR................893
      STARTING MOTOR................894
      ENGINE STARTING DEVICE................895
  12 TESTING AND ADJUSTING................896
    TESTING AND ADJUSTING................897
      ADJUSTING VALVLE CLEARANCE................897
      MEASURING COMPRESSION PRESSURE................899
      ADJUSTING FUEL INJECTION PRESSURE................900
      TESTING AND ADJUSTING FUEL INJECTION TIMING................901
      ADJUSTING FUEL CUT SOLENOID................905
    FUEL INJECTION PUMP CALIBRATION DATA................908
    PERFORMANCE TEST ................911
      RUN-IN STANDARD................911
      PERFORMANCE TEST CRITERIA ................912
    TROUBLESHOOTING................914
      METHOD OF USING TROUBLESHOOTING CHARTS................915
      POINTS TO REMEMBER WHEN TROUBLESHOOTING................919
      S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)................920
      S-2 ENGINE DOES NOT START................921
        (1) ENGINE DOES NOT TURN................921
        (2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED)................922
        (3) EXHAUST SMOKE COMES OUT, BUT ENGINE DOES NOT START (FUEL IS NOT BEING INJECTED)................923
      S-3 ENGINE DOES NOT PICK UP SMOOTHLY................924
      S-4 ENGINE STOPS DURING OPERATIONS................925
      S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)................926
      S-6 ENGINE LACK OUTPUT (NO POWER)................927
      S-7 EXHAUST GAS IS BLACK................928
      S-8 OIL CONSUMPTION IS EXCESSIVE, OR EXHAUST GAS IS BLUE................929
      S-9 OIL BECOMES CONTAMINATED QUICKLY................930
      S-10 FUEL CONSUMPTION IS EXCESSIVE................931
      S-11 OIL IS IN COOLING WATER ................932
      S-12 OIL PRESSURE CAUTION LAMP LIGHTS UPS (DROP IN OIL PRESSURE)................933
      S-13 OIL LEVEL RISES (WATER, FUEL IN OIL )................934
      S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)................935
      S-15 ABNORMAL NOISE IS MADE................936
      S-16 VIBRATION IS EXCESSIVE................937
    TESTING AND ADJUSTING TOOL LIST................938
    TESTING AND ADJUSTING DATA................939
  13 DISASSEMBLY AND ASSEMBLY................941
    SPECIAL TOOL LIST................942
    OVERALL DISASSEMBLY OF 4D95LC-2................943
      PREPARATORY WORK................944
      1. ALTERNATOR, FAN PULLEY................944
      2. STARTING MOTOR, ENGINE STOP SOLENOID, FUEL AND OIL FILTERS, DIPSTICK................945
      3. WATER PUMP................945
      4. FUEL INJECTION TUBE, GLOW PLUG................945
      5. INJECTION NOZZLE................945
      6. FUEL INJECTION PUMP................946
      7. INTAKE MANIFOLD................946
      8. EXHAUST MANIFOLD................946
      9. HEAD COVER................946
      10. ROCKER ARM................947
      11. PUSH ROD, CYLINDER HEAD MOUNTING BOLT................947
      12. CYLINDER HEAD COVER................947
      13. PTO SHAFT................948
      14. OIL PAN................949
      15. OIL SUCTION PIPE................949
      16. CRANKSHAFT PULLEY................949
      17. GEAR CASE COVER................949
      18. OIL PUMP, IDLER GEAR................950
      19. CAMSHAFT ASSEMBLY................950
      20. FLYWHEEL................950
      21. FLYWHEEL HOUSING................951
      22. PISTION, CONNECTING ROD ASSEMBLY................951
      23. MAIN CAP................953
      24. CRANKSHAFT................954
      25. TAPPET................954
      26.CYLINDER BLOCK ASSEMBLY................954
    OVERALL ASSEMBLY................955
      1. CYLINDER BLOCK ASSEMBLY................955
      2. TAPPET................955
      3. CRANKSHAFT................955
      4. MAIN CAP................956
      5. FLYWHEEL HOUSING................959
      6. FLYWHEEL................960
      7. CAMSHAFT ASSEMBLY................960
      8. OIL PUMP, IDLER GEAR................961
      9. GEAR CASE COVER................962
      10. CRANKSHAFT PULLEY................962
      11. OIL SUCTION PIPE................962
      12. OIL PAN................963
      13. PTO SHAFT................963
      14. FUEL INJECTION PUMP................963
      15. CYLINDER HEAD ASSEMBLY................964
      16. ADJUSTMENT OF VALVE CLEARANCE................966
      17. HEAD COVER................967
      18. EXHAUST MANIFOLD................967
      19. INTAKE MANIFOLD................967
      20. INJECTION NOZZLE................967
      21. FUEL INJECTION TUBE, GLOW PLUG................968
      22. WATER PUMP................968
      23. STARTING MOTOR. ENGINE STOP SOLENOID, FUEL AND OIL FILTERS, DIPSTICK................968
      24. ALTERNATOR, FAN PULLEY................969
      25. ENGINE ASSEMBLY................969
      26. FAN, EXHAUST PIPE, MUFFLER, ENGINE OIL TUBES, BLOCK, COVER................970
  14 MAINTENANCE STANDARD................971
    CYLINDER HEAD................972
    VALVE AND VALVE GUIDE................973
    ROCKER ARM SHAFT, PUSH ROD AND TAPPET................974
    CYLINDER BLOCK................975
    CYLINDER................976
    CRANKSHAFT................977
    CAMSHAFT................978
    TIMING GEAR................979
    PISTION, PISTON RING AND PISTION PIN................980
    CONNECTING ROD................981
    FLYWHEEL AND FLYWHEEL HOUSING................982
    OIL PUMP................983
    REGULATOR VALVE................984
    WATER PUMP AND THERMOSTAT................985
  15 REPAIR AND REPLACEMENT OF PARTS................986
    CYLINDER HEAD SECTION................987
      GRINDING CYLINDER HEAD MOUNTING SURFACE................987
      REPLACING VALVE GUIDE................988
      GRINDING VALVE................989
    CYLINDER BLOCK SECTION................990
      REPLACING CAMSHAFT BUSHING................990
      REPLACING CRANKSHAFT GEAR................992
      REPLACING CAM GEAR................993
      REPLACING FLYWHEEL RING GEAR................994
      PROCEDURE FOR PRESSURE TEST ................995
      CYLINDER LINER (SPECIAL RESTORATION PART)................996
      MACHINING DRAWING FOR CYLINDER BLOCK BORE................997
      ADDITIONAL MACHINING OF CAM JOURNAL................998
      GRINDING CRANKSHAFT................999
      REPLACING CONNECTING ROD SMALL END BUSHING................1000
SEBM031001 - 95-3 Series Diesel Engines Shop Manual................1002
  SAFETY ................1006
    SAFETY NOTICE ................1006
  FOREWORD ................1008
    GENERAL ................1008
    STANDARD TIGHTENING TORQUE ................1015
    CONVERSION TABLE ................1019
  SPECIFICATIONS ................1031
  OVERALL DRAWING ................1037
  GENERAL STRUCTURE ................1047
  INTAKE AND EXHAUST SYSTEM ................1049
  AIR CLEANER ................1053
  CYLINDER ................1066
  MAIN CIRCULATION SYSTEM ................1067
  CRANKSHAFT ................1071
  CONNECTING ROD ................1075
  TIMING GEAR ................1081
  CAMSHAFT ................1087
  ROCKER ARM SHAFT, PUSH ROD AND TAPPET ................1088
  OIL PUMP ................1091
  OIL FILTER ................1098
  FUEL SYSTEM CHART ................1100
  FUEL INJECTION PUMP ................1103
  COOLING SYSTEM CHART ................1114
  WATER PUMP ................1115
  STARTING AND CHARGING SYSTEM ELECTRICAL CIRCUIT DIAGRAM ................1121
  ADJUSTING VALVE CLEARANCE ................1129
  MEASURING COMPRESSION PRESSURE ................1131
  ADJUSTING FUEL INJECTION PRESSURE ( CRACKING PRESSURE) ................1132
  PERFORMANCE TEST ................1145
  METHOD OF USING TROUBLESHOOTING CHARTS ................1151
  POINTS TO REMEMBER WHEN TROUBLESHOOTING ................1155
  TESTING AND ADJUSTING TOOL LIST ................1174
  SPECIAL TOOL LIST ................1179
  OVERALL DISASSEMBLY, ASSEMBLY ................1180
  DISASSEMBLY ................1181
  ASSEMBLY ................1193
  GRINDING CYLINDER HEAD MOUNTING SURFACE ................1211
  REPLACING VALVE GUIDE ................1212
  GRINDING VALVE ................1213
  REPLACING CAMSHAFT BUSHING ................1214
  REPLACING CRANKSHAFT GEAR ................1216
  REPLACING CAM GEAR ................1217
  REPLACING FLYWHEEL RING GEAR ................1218
  PROCEDURE FOR PRESSURE TEST ................1219
  CYLINDER LINER ( SPECIAL RESTORATION PART) ................1220
  MACHINING DRAWING FOR CYLINDER BLOCK BORE ................1221
  GRINDING CRANKSHAFT ................1223
SEN04408-00 - 95 Series Diesel Engine Shop Manual................1226
  SEN04408-00 WA65-6, WA70-6, WA80-6................1226
  CONTENTS................1227
  SAFETY................1227
  FOREWORD................1229
  01 GENERAL................1248
    General................1249
    General view................1251
    4D95LWE-5................1251
    S4D95LWE-5................1253
    Specifications................1255
    General assembly drawing................1257
    4D95LWE-5 LEFT SIDE VIEW (WA65HH-6)................1257
    4D95LWE-5 RIGHT SIDE VIEW (WA65HH-6)................1258
    4D95LWE-5 FRONT VIEW (WA65HH-6)................1259
    4D95LWE-5 REAR VIEW (WA65HH-6)................1260
    S4D95LWE-5 LEFT SIDE VIEW (WA80HH-6)................1261
    S4D95LWE-5 RIGHT SIDE VIEW (WA80HH-6)................1262
    S4D95LWE-5 FRONT VIEW (WA80HH-6)................1263
    S4D95LWE-5 REAR VIEW (WA80HH-6)................1264
    DIMENSION TABLE................1265
    Engine performance curve................1266
    4D95LWE-5 [Applicable machine: WA65-HH-6]................1266
    4D95LWE-5 [Applicable machine: WA70-HH-6]................1267
    4D95LWE-5 [Applicable machine: WA80-HH-6]................1268
    Weight table................1269
  11 STRUCTURE AND FUNCTION................1270
    General structure................1271
    EXHAUST SYSTEM................1275
      Turbocharger................1275
      TD04L................1275
        Outline of waste gate valve................1276
    ENGINE BODY................1277
      Cylinder head................1277
        4D95LWE-5................1277
        Cylinder head................1278
        Head cover................1278
        S4D95LWE-5................1279
        Cylinder head................1280
        Head cover................1280
      Cylinder block................1281
      Main moving parts................1283
      Timing gear................1285
      WITHOUT FRONT PTO TYPE (HELICAL GEAR)................1285
        Front oil seal................1286
      Valve system................1287
      Flywheel and flywheel housing................1289
      WITHOUT REAR PTO TYPE................1289
    LUBRICATION SYSTEM................1291
      Lubrication system chart................1291
      Oil pump................1292
        Specifications................1292
        Oil pump................1292
        Regulator valve................1292
      Oil filter................1293
        Relief valve................1293
    FUEL SYSTEM................1294
      Fuel system chart................1294
      Fuel injection pump................1295
      Fuel injection nozzle................1297
      For direct fuel injection type................1297
      For swirl chamber type................1297
        Fuel injection nozzle................1297
    COOLING STSTEM................1298
      Cooling system chart................1298
      Thermostat and fan drive................1299
      THERMOSTAT (WITHOUT JIGGLE VALVE)................1301
    ELECTRICAL SYSTEM................1302
      Starting and charging system electrical circuit diagram................1302
      Alternator................1303
      ALTERNATOR WITH BUILT-IN REGULATOR (Open type, 90A)................1303
      Starting motor................1305
        For 2.2 kW................1305
      Engine starting device................1306
      GLOW PLUG (METAL 2-WIRE TYPE GLOW PLUG)................1306
        1. Connector (round 8-pin), (Short 8-pin)................1307
        2. Lead wire................1307
        3. Case................1307
        4. Bracket................1307
        5. Label................1307
        1. Water temperature sensor................1307
        1. Glow relay................1307
        2. Lead wire................1307
        3. Connector (round 2-in)................1307
  12 TESTING AND ADJUSTING................1308
    Performance test................1309
    Run-in standard................1309
    Performance test criteria................1311
    Testing and adjusting data................1313
    Testing and adjusting tools list................1314
    Intake and exhaust system................1315
    Adjusting valve clearance................1315
    Engine body................1317
    Measuring compression pressure................1317
      Measurement procedure................1317
    Fuel system................1318
    Adjusting fuel injection pressure (Cracking pressure)................1318
    Shim data for adjusting injection pressure................1319
    Testing and adjusting fuel injection timing................1320
    Table of injection pumps using plunger with stepped lead................1325
    Adjusting fuel injection rate................1326
    Governor adjustment standard................1327
    Troubleshooting................1330
    Method of using troubleshooting charts................1331
    Points on troubleshooting................1335
    S-1 Starting performance is poor (Starting always takes time)................1336
    S-2 Engine does not start................1337
      1) Engine does not turn................1337
      2) Engine turns but no exhaust gas comes out (Fuel is not being injected)................1338
      3) Exhaust gas comes out but engine does not start (Fuel is being injected)................1339
    S-3 Engine does not pick up smoothly (Follow-up is poor)................1340
    S-4 Engine stops during operations................1341
    S-5 Engine does not rotate smoothly................1342
    S-6 Engine lacks output (no power)................1343
    S-7 Exhaust gas is black (incomplete combustion)................1344
    S-8 Oil consumption is excessive (or exhaust gas is blue)................1345
    S-9 Oil becomes contaminated quickly................1346
    S-10 Fuel consumption is excessive................1347
    S-11 Oil is in coolant, or coolant spurts back, or coolant level goes down................1348
    S-12 Oil pressure lamp lights up (drop in oil pressure)................1349
    S-13 Oil level rises................1350
    S-14 Coolant temperature becomes too high (overheating)................1351
    S-15 Abnormal noise is made................1352
    S-16 Vibration is excessive................1353
  13 DISASSEMLY AND ASSEMBLY................1354
    General disassembly................1355
      Special tools................1355
    General assembly................1367
      Special tools................1367
  14 MAINTENANCE STANDARD................1386
    Turbocharger................1387
    Cylinder head................1389
    Valve, valve guide................1391
    Rocker arm shaft, push rod and tappet................1392
    Cylinder block................1393
    Cylinder................1395
    Crankshaft................1396
    Camshaft................1397
    Timing gear (Helical gear)................1399
    Flywheel and flywheel housing................1400
    Piston, piston ring and piston pin................1401
    Connecting rod................1403
    Regulator valve................1405
    Water pump and thermostat................1406
  15 REPAIR AND REPLACEMENT OF PARTS................1408
    Grinding cylinder head mounting surface................1409
    Replacing valve guide................1410
      Special tools................1410
    Grinding valve................1411
      Special tool................1411
    Replacing camshaft bushing................1412
      Special tools................1412
    Replacing crankshaft gear................1414
    Testing and adjusting fuel injection timing................1415
    Replacing flywheel ring gear................1416
    Procedure for pressure test................1417
      Special tools................1417
    Cylinder liner................1418
    (special restoration part)................1418
      Cylinder liner................1418
    Machining drawing for cylinder block bore................1419
    Additional machining of cam journal................1420
    Grinding crankshaft................1421
      Applicable crankshaft................1421
    Replacing connecting rod small end bushing................1422
      Special tools................1422

Komatsu 95 Series Diesel Engine Repair Service Manuals

Complete service repair manual with Electrical Wiring Diagrams for Komatsu 95 Series Diesel Engines, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

Komatsu 95 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.

SEBE61460114 - 95 Series Diesel Engine Shop Manual.pdf
SEBM018803 - 95-2 Series Diesel Engine Shop Manual.pdf
SEBM031001 - 95-3 Series Diesel Engines Shop Manual.pdf
SEN04408-00 - 95 Series Diesel Engine Shop Manual.pdf

PRODUCT DETAILS:
Total Pages: 1,422 pages
File Format: PDF
Language: English

MAIN SECTIONS
01 GENERAL ....... 01-1
11 STRUCTURE AND FUNCTION .... 11-1
12 TESTING AND ADJUSTING ..... 12-1
13 DISASSEMBLY AND ASSEMBLY .... 13-1
14 MAINTENANCE STANDARD ..... 14-1
15 REPAIR AND REPLACEMENT OF PARTS ... 15-1

SEBE61460114 - 95 Series Diesel Engine Shop Manual................2
  CONTENTS................3
  01 GENERAL ................28
    GENERAL VIEW ................29
    SPECIFICATIONS ................31
    GENERAL ASSEMBLY DRAWING ................53
    ENGINE PERFORMANCE CURVE ................95
    WEIGHT TABLE................155
  11 STRUCTURE AND FUNCTION ................158
    GENERAL STRUCTURE ................159
    INTAKE AND EXHAUST SYSTEM ................170
      INTAKE AND EXHAUST SYSTEM................170
      FTG AIR CLEANER................186
      TURBOCHARGER................190
      AFTER-COOLER................197
    ENGINE BODY................199
      CYLINDER HEAD................199
      VALVE SYSTEM................219
      CYLINDER BLOCK................227
      CYLINDER LINER................233
      MAIN CIRCULATION SYSTEM................235
      TIMING GEAR................253
      FLYWHEEL AND FLYWHEEL HOUSING................259
    LUBRICATION SYSTEM................264
      LUBRICATION SYSTEM CHART................264
      OIL PUMP ................270
      OIL FILTER ................271
      OIL COOLER ................273
    FUEL SYSTEM ................275
      FUEL SYSTEM CHART ................275
      FUEL INJECTION PUMP ................287
      GOVERNOR................317
      FEED PUMP................321
      FUEL INJECTION NOZZLE ................323
      FUEL CUT SOLENOID ................326
      ENGINE STOP MOTOR ................329
      FUEL FILTER ................334
      WATER SEPARATOR ................335
    COOLING SYSTEM ................336
      COOLING SYSTEM CHART ................336
      WATER PUMP ................339
      CORROSION RESISTOR (OPTION) ................342
      THERMOSTAT  AND FAN DRIVE ................343
    ELECTRICAL SYSTEM................353
      ALTERNATOR................353
      STARTING MOTOR ................362
      ELECTRICAL INTAKE AIR HEATER ................368
    ACCESSORY................373
      AIR COMPRESSOR................373
  12 TESTING AND ADJUSTING................376
    INTAKE AND EXHAUST SYSTEM................377
      ADJUSTING VALVE CLEARANCE................377
      MEASURING EXHAUST GAS COLOR................379
    ENGINE BODY................380
      MEASURING COMPRESSION PRESSURE................380
      MEASURING BLOW-BY PRESSURE................381
      ADJUSTING ENGINE SPEED SENSOR................382
    FUEL SYSTEM................383
      CHECKING AND ADJUSTING FUEL INJECTION TIMING................383
      ADJUSTING GOVERNOR................393
      TESTING AND ADJUSTING FUEL CUT SOLENOID................396
      PROCEDURE FOR ADJUSTING ENGINE STOP MOTOR CABLE................401
      ADJUSTING FUEL INJECTION PRESSURE................403
    LUBRICATION SYSTEM................406
      MEASURING OIL PRESSURE................406
      MEASURING OIL TEMPERATURE................407
    COOLING SYSTEM................408
      MEASURING WATER TEMPERATURE................408
      TESTING AND ADJUSTING FAN BELT TENSION................409
    FUEL INJECTION PUMP CALIBRATION DATA................410
    PERFORMANCE TEST................529
      RUN-IN STANDARD................529
      PERFORMANCE TEST CRITERIA................538
      TESTING AND ADJUSTING TOOL LIST................559
      TESTING AND ADJUSTING DATA................560
    TROUBLESHOOTING................583
      METHOD OF USING TROUBLESHOOTING TABLE................584
      POINTS TO REMEMBER WHEN TROUBLESHOOTING................588
      S-1 Starting performance is poor (Starting always takes time) ................589
      S-2 Engine does not start................590
        (1) Engine does not turn................590
        (2) Engine turns but no exhaust gas comes out (Fuel is not being injected)................591
        (3) Exhaust gas comes out but engine does not start (Fuel is being injected)................592
      S-3 Engine does not pick up smoothly (Follow-up is poor) ................593
      S-4 Engine stops during operations ................594
      S-5 Engine does not rotate smoothly ................595
      S-6 Engine lacks output (no power) ................596
      S-7 Exhaust gas is black (incomplete combustion) ................597
      S-8 Oil consumption is excessive (or exhaust gas is blue)................598
      S-9 Oil becomes contaminated quickly ................599
      S-10 Fuel consumption is excessive ................600
      S-11 Oil is in cooling water, or water spurts back, or water level ................601
      S-12 Oil pressure lamp lights up (drop in oil pressure) ................602
      S-13 Oil level rises................603
      S-14 Water temperature becomes too high (overheating) ................604
      S-15 Abnormal noise is made................605
      S-16 Vibration is excessive................606
      S-17 Diagnosis of electronical governor by diagnosis display (electronical governor made by ZEXEL)................607
  13 DISASSEMBLY AND ASSEMBLY................623
    3D95S-W-1................624
      GENERAL DISASSEMBLY................625
      GENERAL ASSEMBLY ................632
    4D95S-1................645
      GENERAL DISASSEMBLY................646
      GENERAL ASSEMBLY ................656
    4D95L SERIES................672
      GENERAL DISASSEMBLY................672
      GENERAL ASSEMBLY................686
    6D95L SERIES................708
      GENERAL DISASSEMBLY................708
      GENERAL ASSEMBLY................722
    DISASSEMBLY AND ASSEMBLY OF AIR COMPRESSOR................746
  14 MAINTENANCE STANDARD ................753
    TURBOCHARGER ................754
    CYLINDER HEAD ................757
    VALVE, VALVE GUIDE................762
    ROCKER ARM SHAFT, PUSH ROD AND TAPPET................765
    CYLINDER BLOCK ................766
    CRANKSHAFT ................768
    CAMSHAFT ................772
    TIMING GEAR (HELICAL GEAR) ................778
    FLYWHEEL AND FLYWHEEL HOUSING ................783
    PISTON, PISTON RING AND PISTON PIN................784
    CONNECTING ROD ................793
    OIL PUMP ................794
    REGULATOR VALVE ................796
    WATER PUMP, THERMOSTAT ................797
    FUEL SYSTEM ................800
  15 REPAIR AND REPLACEMENT ................803
    CYLINDER HEAD SECTION................805
      GRINDING CYLINDER HEAD  MOUNTING  SURFACE ................805
      REPLACING VALVE SEAT INSERT................806
      REPLACING VALVE GUIDE ................810
      GRINDING VALVE ................811
    CYLINDER BLOCK SECTION................812
      REPLACING CAM BUSHING ................812
      REPLACING GEARS................814
      PROCEDURE FOR PRESSURE TEST ................816
      CYLINDER LINER (SPECIAL RESTORATION PART) ................817
      MACHINING DRAWING FOR CYLINDER BLOCK BORE ................818
      ADDITIONAL MACHINING OF CAM JOURNAL ................819
      GRINDING CRANKSHAFT ................820
SEBM018803 - 95-2 Series Diesel Engine Shop Manual................822
  COVER................822
  CONTENTS................823
  SAFETY................826
    SAFETY NOTICE................826
  FOREWORD................828
    GENERAL................828
    HOW TO READ THE SHOP MANUAL................829
    HOISTING INSTRUCTIONS................830
    METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER................831
    COATING MATERIALS................833
    STANDARD TIGHTENING TORQUE................835
    ELECTRIC WIRE CODE................838
    CONVERSION TABLE................839
    UNITS................845
  01 GENERAL................846
    APPLICABLE MACHINE................847
    SPECIFICATIONS................848
    WEIGHT TABLE................850
    OVERALL DRAWING ................851
    ENGINE PERFORMANCE CURVE................854
  11 STRUCTURE AND FUNCTION................857
    GENERAL STRUCTURE................858
      GENERAL STRUCTURE................858
    INTAKE AND EXHAUST SYSTEM ................860
      INTAKE AND EXHAUST SYSTEM ................860
      AIR CLEANER................862
    ENGINE BODY................864
      CYLINDER HEAD................864
      CYLINDER BLOCK................866
      MAIN CIRCULATION SYSTEM................868
      TIMING GEAR................870
      VALVE SYSTEM ................872
      FLYWHEEL AND FLYWHEEL HOUSING................874
    LUBRICATION SYSTEM ................876
      LUBRICATION SYSTEM CHART................876
      OIL PUMP................877
      OIL FILTER ................878
      OIL FILTER MOUNT................879
    FUEL SYSTEM ................881
      FUEL SYSTEM CHART................881
      FUEL INJECTION PUMP................882
      FUEL INJECTION NOZZLE................884
      FUEL FILTER................885
      ENGINE CUT SOLENOID................886
    COOLING SYSTEM................887
      COOLING SYSTEM CHART................887
      WATER PUMP................888
      FAN DRIVE AND THERMOSTAT................889
    ELECTRICAL SYSTEM ................892
      STARTING AND CHARGING SYSTEM ELECTRICAL CIRCUIT DIAGRAM................892
      ALTERNATOR................893
      STARTING MOTOR................894
      ENGINE STARTING DEVICE................895
  12 TESTING AND ADJUSTING................896
    TESTING AND ADJUSTING................897
      ADJUSTING VALVLE CLEARANCE................897
      MEASURING COMPRESSION PRESSURE................899
      ADJUSTING FUEL INJECTION PRESSURE................900
      TESTING AND ADJUSTING FUEL INJECTION TIMING................901
      ADJUSTING FUEL CUT SOLENOID................905
    FUEL INJECTION PUMP CALIBRATION DATA................908
    PERFORMANCE TEST ................911
      RUN-IN STANDARD................911
      PERFORMANCE TEST CRITERIA ................912
    TROUBLESHOOTING................914
      METHOD OF USING TROUBLESHOOTING CHARTS................915
      POINTS TO REMEMBER WHEN TROUBLESHOOTING................919
      S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)................920
      S-2 ENGINE DOES NOT START................921
        (1) ENGINE DOES NOT TURN................921
        (2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED)................922
        (3) EXHAUST SMOKE COMES OUT, BUT ENGINE DOES NOT START (FUEL IS NOT BEING INJECTED)................923
      S-3 ENGINE DOES NOT PICK UP SMOOTHLY................924
      S-4 ENGINE STOPS DURING OPERATIONS................925
      S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)................926
      S-6 ENGINE LACK OUTPUT (NO POWER)................927
      S-7 EXHAUST GAS IS BLACK................928
      S-8 OIL CONSUMPTION IS EXCESSIVE, OR EXHAUST GAS IS BLUE................929
      S-9 OIL BECOMES CONTAMINATED QUICKLY................930
      S-10 FUEL CONSUMPTION IS EXCESSIVE................931
      S-11 OIL IS IN COOLING WATER ................932
      S-12 OIL PRESSURE CAUTION LAMP LIGHTS UPS (DROP IN OIL PRESSURE)................933
      S-13 OIL LEVEL RISES (WATER, FUEL IN OIL )................934
      S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)................935
      S-15 ABNORMAL NOISE IS MADE................936
      S-16 VIBRATION IS EXCESSIVE................937
    TESTING AND ADJUSTING TOOL LIST................938
    TESTING AND ADJUSTING DATA................939
  13 DISASSEMBLY AND ASSEMBLY................941
    SPECIAL TOOL LIST................942
    OVERALL DISASSEMBLY OF 4D95LC-2................943
      PREPARATORY WORK................944
      1. ALTERNATOR, FAN PULLEY................944
      2. STARTING MOTOR, ENGINE STOP SOLENOID, FUEL AND OIL FILTERS, DIPSTICK................945
      3. WATER PUMP................945
      4. FUEL INJECTION TUBE, GLOW PLUG................945
      5. INJECTION NOZZLE................945
      6. FUEL INJECTION PUMP................946
      7. INTAKE MANIFOLD................946
      8. EXHAUST MANIFOLD................946
      9. HEAD COVER................946
      10. ROCKER ARM................947
      11. PUSH ROD, CYLINDER HEAD MOUNTING BOLT................947
      12. CYLINDER HEAD COVER................947
      13. PTO SHAFT................948
      14. OIL PAN................949
      15. OIL SUCTION PIPE................949
      16. CRANKSHAFT PULLEY................949
      17. GEAR CASE COVER................949
      18. OIL PUMP, IDLER GEAR................950
      19. CAMSHAFT ASSEMBLY................950
      20. FLYWHEEL................950
      21. FLYWHEEL HOUSING................951
      22. PISTION, CONNECTING ROD ASSEMBLY................951
      23. MAIN CAP................953
      24. CRANKSHAFT................954
      25. TAPPET................954
      26.CYLINDER BLOCK ASSEMBLY................954
    OVERALL ASSEMBLY................955
      1. CYLINDER BLOCK ASSEMBLY................955
      2. TAPPET................955
      3. CRANKSHAFT................955
      4. MAIN CAP................956
      5. FLYWHEEL HOUSING................959
      6. FLYWHEEL................960
      7. CAMSHAFT ASSEMBLY................960
      8. OIL PUMP, IDLER GEAR................961
      9. GEAR CASE COVER................962
      10. CRANKSHAFT PULLEY................962
      11. OIL SUCTION PIPE................962
      12. OIL PAN................963
      13. PTO SHAFT................963
      14. FUEL INJECTION PUMP................963
      15. CYLINDER HEAD ASSEMBLY................964
      16. ADJUSTMENT OF VALVE CLEARANCE................966
      17. HEAD COVER................967
      18. EXHAUST MANIFOLD................967
      19. INTAKE MANIFOLD................967
      20. INJECTION NOZZLE................967
      21. FUEL INJECTION TUBE, GLOW PLUG................968
      22. WATER PUMP................968
      23. STARTING MOTOR. ENGINE STOP SOLENOID, FUEL AND OIL FILTERS, DIPSTICK................968
      24. ALTERNATOR, FAN PULLEY................969
      25. ENGINE ASSEMBLY................969
      26. FAN, EXHAUST PIPE, MUFFLER, ENGINE OIL TUBES, BLOCK, COVER................970
  14 MAINTENANCE STANDARD................971
    CYLINDER HEAD................972
    VALVE AND VALVE GUIDE................973
    ROCKER ARM SHAFT, PUSH ROD AND TAPPET................974
    CYLINDER BLOCK................975
    CYLINDER................976
    CRANKSHAFT................977
    CAMSHAFT................978
    TIMING GEAR................979
    PISTION, PISTON RING AND PISTION PIN................980
    CONNECTING ROD................981
    FLYWHEEL AND FLYWHEEL HOUSING................982
    OIL PUMP................983
    REGULATOR VALVE................984
    WATER PUMP AND THERMOSTAT................985
  15 REPAIR AND REPLACEMENT OF PARTS................986
    CYLINDER HEAD SECTION................987
      GRINDING CYLINDER HEAD MOUNTING SURFACE................987
      REPLACING VALVE GUIDE................988
      GRINDING VALVE................989
    CYLINDER BLOCK SECTION................990
      REPLACING CAMSHAFT BUSHING................990
      REPLACING CRANKSHAFT GEAR................992
      REPLACING CAM GEAR................993
      REPLACING FLYWHEEL RING GEAR................994
      PROCEDURE FOR PRESSURE TEST ................995
      CYLINDER LINER (SPECIAL RESTORATION PART)................996
      MACHINING DRAWING FOR CYLINDER BLOCK BORE................997
      ADDITIONAL MACHINING OF CAM JOURNAL................998
      GRINDING CRANKSHAFT................999
      REPLACING CONNECTING ROD SMALL END BUSHING................1000
SEBM031001 - 95-3 Series Diesel Engines Shop Manual................1002
  SAFETY ................1006
    SAFETY NOTICE ................1006
  FOREWORD ................1008
    GENERAL ................1008
    STANDARD TIGHTENING TORQUE ................1015
    CONVERSION TABLE ................1019
  SPECIFICATIONS ................1031
  OVERALL DRAWING ................1037
  GENERAL STRUCTURE ................1047
  INTAKE AND EXHAUST SYSTEM ................1049
  AIR CLEANER ................1053
  CYLINDER ................1066
  MAIN CIRCULATION SYSTEM ................1067
  CRANKSHAFT ................1071
  CONNECTING ROD ................1075
  TIMING GEAR ................1081
  CAMSHAFT ................1087
  ROCKER ARM SHAFT, PUSH ROD AND TAPPET ................1088
  OIL PUMP ................1091
  OIL FILTER ................1098
  FUEL SYSTEM CHART ................1100
  FUEL INJECTION PUMP ................1103
  COOLING SYSTEM CHART ................1114
  WATER PUMP ................1115
  STARTING AND CHARGING SYSTEM ELECTRICAL CIRCUIT DIAGRAM ................1121
  ADJUSTING VALVE CLEARANCE ................1129
  MEASURING COMPRESSION PRESSURE ................1131
  ADJUSTING FUEL INJECTION PRESSURE ( CRACKING PRESSURE) ................1132
  PERFORMANCE TEST ................1145
  METHOD OF USING TROUBLESHOOTING CHARTS ................1151
  POINTS TO REMEMBER WHEN TROUBLESHOOTING ................1155
  TESTING AND ADJUSTING TOOL LIST ................1174
  SPECIAL TOOL LIST ................1179
  OVERALL DISASSEMBLY, ASSEMBLY ................1180
  DISASSEMBLY ................1181
  ASSEMBLY ................1193
  GRINDING CYLINDER HEAD MOUNTING SURFACE ................1211
  REPLACING VALVE GUIDE ................1212
  GRINDING VALVE ................1213
  REPLACING CAMSHAFT BUSHING ................1214
  REPLACING CRANKSHAFT GEAR ................1216
  REPLACING CAM GEAR ................1217
  REPLACING FLYWHEEL RING GEAR ................1218
  PROCEDURE FOR PRESSURE TEST ................1219
  CYLINDER LINER ( SPECIAL RESTORATION PART) ................1220
  MACHINING DRAWING FOR CYLINDER BLOCK BORE ................1221
  GRINDING CRANKSHAFT ................1223
SEN04408-00 - 95 Series Diesel Engine Shop Manual................1226
  SEN04408-00 WA65-6, WA70-6, WA80-6................1226
  CONTENTS................1227
  SAFETY................1227
  FOREWORD................1229
  01 GENERAL................1248
    General................1249
    General view................1251
    4D95LWE-5................1251
    S4D95LWE-5................1253
    Specifications................1255
    General assembly drawing................1257
    4D95LWE-5 LEFT SIDE VIEW (WA65HH-6)................1257
    4D95LWE-5 RIGHT SIDE VIEW (WA65HH-6)................1258
    4D95LWE-5 FRONT VIEW (WA65HH-6)................1259
    4D95LWE-5 REAR VIEW (WA65HH-6)................1260
    S4D95LWE-5 LEFT SIDE VIEW (WA80HH-6)................1261
    S4D95LWE-5 RIGHT SIDE VIEW (WA80HH-6)................1262
    S4D95LWE-5 FRONT VIEW (WA80HH-6)................1263
    S4D95LWE-5 REAR VIEW (WA80HH-6)................1264
    DIMENSION TABLE................1265
    Engine performance curve................1266
    4D95LWE-5 [Applicable machine: WA65-HH-6]................1266
    4D95LWE-5 [Applicable machine: WA70-HH-6]................1267
    4D95LWE-5 [Applicable machine: WA80-HH-6]................1268
    Weight table................1269
  11 STRUCTURE AND FUNCTION................1270
    General structure................1271
    EXHAUST SYSTEM................1275
      Turbocharger................1275
      TD04L................1275
        Outline of waste gate valve................1276
    ENGINE BODY................1277
      Cylinder head................1277
        4D95LWE-5................1277
        Cylinder head................1278
        Head cover................1278
        S4D95LWE-5................1279
        Cylinder head................1280
        Head cover................1280
      Cylinder block................1281
      Main moving parts................1283
      Timing gear................1285
      WITHOUT FRONT PTO TYPE (HELICAL GEAR)................1285
        Front oil seal................1286
      Valve system................1287
      Flywheel and flywheel housing................1289
      WITHOUT REAR PTO TYPE................1289
    LUBRICATION SYSTEM................1291
      Lubrication system chart................1291
      Oil pump................1292
        Specifications................1292
        Oil pump................1292
        Regulator valve................1292
      Oil filter................1293
        Relief valve................1293
    FUEL SYSTEM................1294
      Fuel system chart................1294
      Fuel injection pump................1295
      Fuel injection nozzle................1297
      For direct fuel injection type................1297
      For swirl chamber type................1297
        Fuel injection nozzle................1297
    COOLING STSTEM................1298
      Cooling system chart................1298
      Thermostat and fan drive................1299
      THERMOSTAT (WITHOUT JIGGLE VALVE)................1301
    ELECTRICAL SYSTEM................1302
      Starting and charging system electrical circuit diagram................1302
      Alternator................1303
      ALTERNATOR WITH BUILT-IN REGULATOR (Open type, 90A)................1303
      Starting motor................1305
        For 2.2 kW................1305
      Engine starting device................1306
      GLOW PLUG (METAL 2-WIRE TYPE GLOW PLUG)................1306
        1. Connector (round 8-pin), (Short 8-pin)................1307
        2. Lead wire................1307
        3. Case................1307
        4. Bracket................1307
        5. Label................1307
        1. Water temperature sensor................1307
        1. Glow relay................1307
        2. Lead wire................1307
        3. Connector (round 2-in)................1307
  12 TESTING AND ADJUSTING................1308
    Performance test................1309
    Run-in standard................1309
    Performance test criteria................1311
    Testing and adjusting data................1313
    Testing and adjusting tools list................1314
    Intake and exhaust system................1315
    Adjusting valve clearance................1315
    Engine body................1317
    Measuring compression pressure................1317
      Measurement procedure................1317
    Fuel system................1318
    Adjusting fuel injection pressure (Cracking pressure)................1318
    Shim data for adjusting injection pressure................1319
    Testing and adjusting fuel injection timing................1320
    Table of injection pumps using plunger with stepped lead................1325
    Adjusting fuel injection rate................1326
    Governor adjustment standard................1327
    Troubleshooting................1330
    Method of using troubleshooting charts................1331
    Points on troubleshooting................1335
    S-1 Starting performance is poor (Starting always takes time)................1336
    S-2 Engine does not start................1337
      1) Engine does not turn................1337
      2) Engine turns but no exhaust gas comes out (Fuel is not being injected)................1338
      3) Exhaust gas comes out but engine does not start (Fuel is being injected)................1339
    S-3 Engine does not pick up smoothly (Follow-up is poor)................1340
    S-4 Engine stops during operations................1341
    S-5 Engine does not rotate smoothly................1342
    S-6 Engine lacks output (no power)................1343
    S-7 Exhaust gas is black (incomplete combustion)................1344
    S-8 Oil consumption is excessive (or exhaust gas is blue)................1345
    S-9 Oil becomes contaminated quickly................1346
    S-10 Fuel consumption is excessive................1347
    S-11 Oil is in coolant, or coolant spurts back, or coolant level goes down................1348
    S-12 Oil pressure lamp lights up (drop in oil pressure)................1349
    S-13 Oil level rises................1350
    S-14 Coolant temperature becomes too high (overheating)................1351
    S-15 Abnormal noise is made................1352
    S-16 Vibration is excessive................1353
  13 DISASSEMLY AND ASSEMBLY................1354
    General disassembly................1355
      Special tools................1355
    General assembly................1367
      Special tools................1367
  14 MAINTENANCE STANDARD................1386
    Turbocharger................1387
    Cylinder head................1389
    Valve, valve guide................1391
    Rocker arm shaft, push rod and tappet................1392
    Cylinder block................1393
    Cylinder................1395
    Crankshaft................1396
    Camshaft................1397
    Timing gear (Helical gear)................1399
    Flywheel and flywheel housing................1400
    Piston, piston ring and piston pin................1401
    Connecting rod................1403
    Regulator valve................1405
    Water pump and thermostat................1406
  15 REPAIR AND REPLACEMENT OF PARTS................1408
    Grinding cylinder head mounting surface................1409
    Replacing valve guide................1410
      Special tools................1410
    Grinding valve................1411
      Special tool................1411
    Replacing camshaft bushing................1412
      Special tools................1412
    Replacing crankshaft gear................1414
    Testing and adjusting fuel injection timing................1415
    Replacing flywheel ring gear................1416
    Procedure for pressure test................1417
      Special tools................1417
    Cylinder liner................1418
    (special restoration part)................1418
      Cylinder liner................1418
    Machining drawing for cylinder block bore................1419
    Additional machining of cam journal................1420
    Grinding crankshaft................1421
      Applicable crankshaft................1421
    Replacing connecting rod small end bushing................1422
      Special tools................1422

Komatsu 95 Series Diesel Engine Repair Service Manuals

Complete service repair manual with Electrical Wiring Diagrams for Komatsu 95 Series Diesel Engines, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

Komatsu 95 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.

SEBE61460114 - 95 Series Diesel Engine Shop Manual.pdf
SEBM018803 - 95-2 Series Diesel Engine Shop Manual.pdf
SEBM031001 - 95-3 Series Diesel Engines Shop Manual.pdf
SEN04408-00 - 95 Series Diesel Engine Shop Manual.pdf

PRODUCT DETAILS:
Total Pages: 1,422 pages
File Format: PDF
Language: English

MAIN SECTIONS
01 GENERAL ....... 01-1
11 STRUCTURE AND FUNCTION .... 11-1
12 TESTING AND ADJUSTING ..... 12-1
13 DISASSEMBLY AND ASSEMBLY .... 13-1
14 MAINTENANCE STANDARD ..... 14-1
15 REPAIR AND REPLACEMENT OF PARTS ... 15-1

SEBE61460114 - 95 Series Diesel Engine Shop Manual................2
  CONTENTS................3
  01 GENERAL ................28
    GENERAL VIEW ................29
    SPECIFICATIONS ................31
    GENERAL ASSEMBLY DRAWING ................53
    ENGINE PERFORMANCE CURVE ................95
    WEIGHT TABLE................155
  11 STRUCTURE AND FUNCTION ................158
    GENERAL STRUCTURE ................159
    INTAKE AND EXHAUST SYSTEM ................170
      INTAKE AND EXHAUST SYSTEM................170
      FTG AIR CLEANER................186
      TURBOCHARGER................190
      AFTER-COOLER................197
    ENGINE BODY................199
      CYLINDER HEAD................199
      VALVE SYSTEM................219
      CYLINDER BLOCK................227
      CYLINDER LINER................233
      MAIN CIRCULATION SYSTEM................235
      TIMING GEAR................253
      FLYWHEEL AND FLYWHEEL HOUSING................259
    LUBRICATION SYSTEM................264
      LUBRICATION SYSTEM CHART................264
      OIL PUMP ................270
      OIL FILTER ................271
      OIL COOLER ................273
    FUEL SYSTEM ................275
      FUEL SYSTEM CHART ................275
      FUEL INJECTION PUMP ................287
      GOVERNOR................317
      FEED PUMP................321
      FUEL INJECTION NOZZLE ................323
      FUEL CUT SOLENOID ................326
      ENGINE STOP MOTOR ................329
      FUEL FILTER ................334
      WATER SEPARATOR ................335
    COOLING SYSTEM ................336
      COOLING SYSTEM CHART ................336
      WATER PUMP ................339
      CORROSION RESISTOR (OPTION) ................342
      THERMOSTAT  AND FAN DRIVE ................343
    ELECTRICAL SYSTEM................353
      ALTERNATOR................353
      STARTING MOTOR ................362
      ELECTRICAL INTAKE AIR HEATER ................368
    ACCESSORY................373
      AIR COMPRESSOR................373
  12 TESTING AND ADJUSTING................376
    INTAKE AND EXHAUST SYSTEM................377
      ADJUSTING VALVE CLEARANCE................377
      MEASURING EXHAUST GAS COLOR................379
    ENGINE BODY................380
      MEASURING COMPRESSION PRESSURE................380
      MEASURING BLOW-BY PRESSURE................381
      ADJUSTING ENGINE SPEED SENSOR................382
    FUEL SYSTEM................383
      CHECKING AND ADJUSTING FUEL INJECTION TIMING................383
      ADJUSTING GOVERNOR................393
      TESTING AND ADJUSTING FUEL CUT SOLENOID................396
      PROCEDURE FOR ADJUSTING ENGINE STOP MOTOR CABLE................401
      ADJUSTING FUEL INJECTION PRESSURE................403
    LUBRICATION SYSTEM................406
      MEASURING OIL PRESSURE................406
      MEASURING OIL TEMPERATURE................407
    COOLING SYSTEM................408
      MEASURING WATER TEMPERATURE................408
      TESTING AND ADJUSTING FAN BELT TENSION................409
    FUEL INJECTION PUMP CALIBRATION DATA................410
    PERFORMANCE TEST................529
      RUN-IN STANDARD................529
      PERFORMANCE TEST CRITERIA................538
      TESTING AND ADJUSTING TOOL LIST................559
      TESTING AND ADJUSTING DATA................560
    TROUBLESHOOTING................583
      METHOD OF USING TROUBLESHOOTING TABLE................584
      POINTS TO REMEMBER WHEN TROUBLESHOOTING................588
      S-1 Starting performance is poor (Starting always takes time) ................589
      S-2 Engine does not start................590
        (1) Engine does not turn................590
        (2) Engine turns but no exhaust gas comes out (Fuel is not being injected)................591
        (3) Exhaust gas comes out but engine does not start (Fuel is being injected)................592
      S-3 Engine does not pick up smoothly (Follow-up is poor) ................593
      S-4 Engine stops during operations ................594
      S-5 Engine does not rotate smoothly ................595
      S-6 Engine lacks output (no power) ................596
      S-7 Exhaust gas is black (incomplete combustion) ................597
      S-8 Oil consumption is excessive (or exhaust gas is blue)................598
      S-9 Oil becomes contaminated quickly ................599
      S-10 Fuel consumption is excessive ................600
      S-11 Oil is in cooling water, or water spurts back, or water level ................601
      S-12 Oil pressure lamp lights up (drop in oil pressure) ................602
      S-13 Oil level rises................603
      S-14 Water temperature becomes too high (overheating) ................604
      S-15 Abnormal noise is made................605
      S-16 Vibration is excessive................606
      S-17 Diagnosis of electronical governor by diagnosis display (electronical governor made by ZEXEL)................607
  13 DISASSEMBLY AND ASSEMBLY................623
    3D95S-W-1................624
      GENERAL DISASSEMBLY................625
      GENERAL ASSEMBLY ................632
    4D95S-1................645
      GENERAL DISASSEMBLY................646
      GENERAL ASSEMBLY ................656
    4D95L SERIES................672
      GENERAL DISASSEMBLY................672
      GENERAL ASSEMBLY................686
    6D95L SERIES................708
      GENERAL DISASSEMBLY................708
      GENERAL ASSEMBLY................722
    DISASSEMBLY AND ASSEMBLY OF AIR COMPRESSOR................746
  14 MAINTENANCE STANDARD ................753
    TURBOCHARGER ................754
    CYLINDER HEAD ................757
    VALVE, VALVE GUIDE................762
    ROCKER ARM SHAFT, PUSH ROD AND TAPPET................765
    CYLINDER BLOCK ................766
    CRANKSHAFT ................768
    CAMSHAFT ................772
    TIMING GEAR (HELICAL GEAR) ................778
    FLYWHEEL AND FLYWHEEL HOUSING ................783
    PISTON, PISTON RING AND PISTON PIN................784
    CONNECTING ROD ................793
    OIL PUMP ................794
    REGULATOR VALVE ................796
    WATER PUMP, THERMOSTAT ................797
    FUEL SYSTEM ................800
  15 REPAIR AND REPLACEMENT ................803
    CYLINDER HEAD SECTION................805
      GRINDING CYLINDER HEAD  MOUNTING  SURFACE ................805
      REPLACING VALVE SEAT INSERT................806
      REPLACING VALVE GUIDE ................810
      GRINDING VALVE ................811
    CYLINDER BLOCK SECTION................812
      REPLACING CAM BUSHING ................812
      REPLACING GEARS................814
      PROCEDURE FOR PRESSURE TEST ................816
      CYLINDER LINER (SPECIAL RESTORATION PART) ................817
      MACHINING DRAWING FOR CYLINDER BLOCK BORE ................818
      ADDITIONAL MACHINING OF CAM JOURNAL ................819
      GRINDING CRANKSHAFT ................820
SEBM018803 - 95-2 Series Diesel Engine Shop Manual................822
  COVER................822
  CONTENTS................823
  SAFETY................826
    SAFETY NOTICE................826
  FOREWORD................828
    GENERAL................828
    HOW TO READ THE SHOP MANUAL................829
    HOISTING INSTRUCTIONS................830
    METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER................831
    COATING MATERIALS................833
    STANDARD TIGHTENING TORQUE................835
    ELECTRIC WIRE CODE................838
    CONVERSION TABLE................839
    UNITS................845
  01 GENERAL................846
    APPLICABLE MACHINE................847
    SPECIFICATIONS................848
    WEIGHT TABLE................850
    OVERALL DRAWING ................851
    ENGINE PERFORMANCE CURVE................854
  11 STRUCTURE AND FUNCTION................857
    GENERAL STRUCTURE................858
      GENERAL STRUCTURE................858
    INTAKE AND EXHAUST SYSTEM ................860
      INTAKE AND EXHAUST SYSTEM ................860
      AIR CLEANER................862
    ENGINE BODY................864
      CYLINDER HEAD................864
      CYLINDER BLOCK................866
      MAIN CIRCULATION SYSTEM................868
      TIMING GEAR................870
      VALVE SYSTEM ................872
      FLYWHEEL AND FLYWHEEL HOUSING................874
    LUBRICATION SYSTEM ................876
      LUBRICATION SYSTEM CHART................876
      OIL PUMP................877
      OIL FILTER ................878
      OIL FILTER MOUNT................879
    FUEL SYSTEM ................881
      FUEL SYSTEM CHART................881
      FUEL INJECTION PUMP................882
      FUEL INJECTION NOZZLE................884
      FUEL FILTER................885
      ENGINE CUT SOLENOID................886
    COOLING SYSTEM................887
      COOLING SYSTEM CHART................887
      WATER PUMP................888
      FAN DRIVE AND THERMOSTAT................889
    ELECTRICAL SYSTEM ................892
      STARTING AND CHARGING SYSTEM ELECTRICAL CIRCUIT DIAGRAM................892
      ALTERNATOR................893
      STARTING MOTOR................894
      ENGINE STARTING DEVICE................895
  12 TESTING AND ADJUSTING................896
    TESTING AND ADJUSTING................897
      ADJUSTING VALVLE CLEARANCE................897
      MEASURING COMPRESSION PRESSURE................899
      ADJUSTING FUEL INJECTION PRESSURE................900
      TESTING AND ADJUSTING FUEL INJECTION TIMING................901
      ADJUSTING FUEL CUT SOLENOID................905
    FUEL INJECTION PUMP CALIBRATION DATA................908
    PERFORMANCE TEST ................911
      RUN-IN STANDARD................911
      PERFORMANCE TEST CRITERIA ................912
    TROUBLESHOOTING................914
      METHOD OF USING TROUBLESHOOTING CHARTS................915
      POINTS TO REMEMBER WHEN TROUBLESHOOTING................919
      S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)................920
      S-2 ENGINE DOES NOT START................921
        (1) ENGINE DOES NOT TURN................921
        (2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED)................922
        (3) EXHAUST SMOKE COMES OUT, BUT ENGINE DOES NOT START (FUEL IS NOT BEING INJECTED)................923
      S-3 ENGINE DOES NOT PICK UP SMOOTHLY................924
      S-4 ENGINE STOPS DURING OPERATIONS................925
      S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)................926
      S-6 ENGINE LACK OUTPUT (NO POWER)................927
      S-7 EXHAUST GAS IS BLACK................928
      S-8 OIL CONSUMPTION IS EXCESSIVE, OR EXHAUST GAS IS BLUE................929
      S-9 OIL BECOMES CONTAMINATED QUICKLY................930
      S-10 FUEL CONSUMPTION IS EXCESSIVE................931
      S-11 OIL IS IN COOLING WATER ................932
      S-12 OIL PRESSURE CAUTION LAMP LIGHTS UPS (DROP IN OIL PRESSURE)................933
      S-13 OIL LEVEL RISES (WATER, FUEL IN OIL )................934
      S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)................935
      S-15 ABNORMAL NOISE IS MADE................936
      S-16 VIBRATION IS EXCESSIVE................937
    TESTING AND ADJUSTING TOOL LIST................938
    TESTING AND ADJUSTING DATA................939
  13 DISASSEMBLY AND ASSEMBLY................941
    SPECIAL TOOL LIST................942
    OVERALL DISASSEMBLY OF 4D95LC-2................943
      PREPARATORY WORK................944
      1. ALTERNATOR, FAN PULLEY................944
      2. STARTING MOTOR, ENGINE STOP SOLENOID, FUEL AND OIL FILTERS, DIPSTICK................945
      3. WATER PUMP................945
      4. FUEL INJECTION TUBE, GLOW PLUG................945
      5. INJECTION NOZZLE................945
      6. FUEL INJECTION PUMP................946
      7. INTAKE MANIFOLD................946
      8. EXHAUST MANIFOLD................946
      9. HEAD COVER................946
      10. ROCKER ARM................947
      11. PUSH ROD, CYLINDER HEAD MOUNTING BOLT................947
      12. CYLINDER HEAD COVER................947
      13. PTO SHAFT................948
      14. OIL PAN................949
      15. OIL SUCTION PIPE................949
      16. CRANKSHAFT PULLEY................949
      17. GEAR CASE COVER................949
      18. OIL PUMP, IDLER GEAR................950
      19. CAMSHAFT ASSEMBLY................950
      20. FLYWHEEL................950
      21. FLYWHEEL HOUSING................951
      22. PISTION, CONNECTING ROD ASSEMBLY................951
      23. MAIN CAP................953
      24. CRANKSHAFT................954
      25. TAPPET................954
      26.CYLINDER BLOCK ASSEMBLY................954
    OVERALL ASSEMBLY................955
      1. CYLINDER BLOCK ASSEMBLY................955
      2. TAPPET................955
      3. CRANKSHAFT................955
      4. MAIN CAP................956
      5. FLYWHEEL HOUSING................959
      6. FLYWHEEL................960
      7. CAMSHAFT ASSEMBLY................960
      8. OIL PUMP, IDLER GEAR................961
      9. GEAR CASE COVER................962
      10. CRANKSHAFT PULLEY................962
      11. OIL SUCTION PIPE................962
      12. OIL PAN................963
      13. PTO SHAFT................963
      14. FUEL INJECTION PUMP................963
      15. CYLINDER HEAD ASSEMBLY................964
      16. ADJUSTMENT OF VALVE CLEARANCE................966
      17. HEAD COVER................967
      18. EXHAUST MANIFOLD................967
      19. INTAKE MANIFOLD................967
      20. INJECTION NOZZLE................967
      21. FUEL INJECTION TUBE, GLOW PLUG................968
      22. WATER PUMP................968
      23. STARTING MOTOR. ENGINE STOP SOLENOID, FUEL AND OIL FILTERS, DIPSTICK................968
      24. ALTERNATOR, FAN PULLEY................969
      25. ENGINE ASSEMBLY................969
      26. FAN, EXHAUST PIPE, MUFFLER, ENGINE OIL TUBES, BLOCK, COVER................970
  14 MAINTENANCE STANDARD................971
    CYLINDER HEAD................972
    VALVE AND VALVE GUIDE................973
    ROCKER ARM SHAFT, PUSH ROD AND TAPPET................974
    CYLINDER BLOCK................975
    CYLINDER................976
    CRANKSHAFT................977
    CAMSHAFT................978
    TIMING GEAR................979
    PISTION, PISTON RING AND PISTION PIN................980
    CONNECTING ROD................981
    FLYWHEEL AND FLYWHEEL HOUSING................982
    OIL PUMP................983
    REGULATOR VALVE................984
    WATER PUMP AND THERMOSTAT................985
  15 REPAIR AND REPLACEMENT OF PARTS................986
    CYLINDER HEAD SECTION................987
      GRINDING CYLINDER HEAD MOUNTING SURFACE................987
      REPLACING VALVE GUIDE................988
      GRINDING VALVE................989
    CYLINDER BLOCK SECTION................990
      REPLACING CAMSHAFT BUSHING................990
      REPLACING CRANKSHAFT GEAR................992
      REPLACING CAM GEAR................993
      REPLACING FLYWHEEL RING GEAR................994
      PROCEDURE FOR PRESSURE TEST ................995
      CYLINDER LINER (SPECIAL RESTORATION PART)................996
      MACHINING DRAWING FOR CYLINDER BLOCK BORE................997
      ADDITIONAL MACHINING OF CAM JOURNAL................998
      GRINDING CRANKSHAFT................999
      REPLACING CONNECTING ROD SMALL END BUSHING................1000
SEBM031001 - 95-3 Series Diesel Engines Shop Manual................1002
  SAFETY ................1006
    SAFETY NOTICE ................1006
  FOREWORD ................1008
    GENERAL ................1008
    STANDARD TIGHTENING TORQUE ................1015
    CONVERSION TABLE ................1019
  SPECIFICATIONS ................1031
  OVERALL DRAWING ................1037
  GENERAL STRUCTURE ................1047
  INTAKE AND EXHAUST SYSTEM ................1049
  AIR CLEANER ................1053
  CYLINDER ................1066
  MAIN CIRCULATION SYSTEM ................1067
  CRANKSHAFT ................1071
  CONNECTING ROD ................1075
  TIMING GEAR ................1081
  CAMSHAFT ................1087
  ROCKER ARM SHAFT, PUSH ROD AND TAPPET ................1088
  OIL PUMP ................1091
  OIL FILTER ................1098
  FUEL SYSTEM CHART ................1100
  FUEL INJECTION PUMP ................1103
  COOLING SYSTEM CHART ................1114
  WATER PUMP ................1115
  STARTING AND CHARGING SYSTEM ELECTRICAL CIRCUIT DIAGRAM ................1121
  ADJUSTING VALVE CLEARANCE ................1129
  MEASURING COMPRESSION PRESSURE ................1131
  ADJUSTING FUEL INJECTION PRESSURE ( CRACKING PRESSURE) ................1132
  PERFORMANCE TEST ................1145
  METHOD OF USING TROUBLESHOOTING CHARTS ................1151
  POINTS TO REMEMBER WHEN TROUBLESHOOTING ................1155
  TESTING AND ADJUSTING TOOL LIST ................1174
  SPECIAL TOOL LIST ................1179
  OVERALL DISASSEMBLY, ASSEMBLY ................1180
  DISASSEMBLY ................1181
  ASSEMBLY ................1193
  GRINDING CYLINDER HEAD MOUNTING SURFACE ................1211
  REPLACING VALVE GUIDE ................1212
  GRINDING VALVE ................1213
  REPLACING CAMSHAFT BUSHING ................1214
  REPLACING CRANKSHAFT GEAR ................1216
  REPLACING CAM GEAR ................1217
  REPLACING FLYWHEEL RING GEAR ................1218
  PROCEDURE FOR PRESSURE TEST ................1219
  CYLINDER LINER ( SPECIAL RESTORATION PART) ................1220
  MACHINING DRAWING FOR CYLINDER BLOCK BORE ................1221
  GRINDING CRANKSHAFT ................1223
SEN04408-00 - 95 Series Diesel Engine Shop Manual................1226
  SEN04408-00 WA65-6, WA70-6, WA80-6................1226
  CONTENTS................1227
  SAFETY................1227
  FOREWORD................1229
  01 GENERAL................1248
    General................1249
    General view................1251
    4D95LWE-5................1251
    S4D95LWE-5................1253
    Specifications................1255
    General assembly drawing................1257
    4D95LWE-5 LEFT SIDE VIEW (WA65HH-6)................1257
    4D95LWE-5 RIGHT SIDE VIEW (WA65HH-6)................1258
    4D95LWE-5 FRONT VIEW (WA65HH-6)................1259
    4D95LWE-5 REAR VIEW (WA65HH-6)................1260
    S4D95LWE-5 LEFT SIDE VIEW (WA80HH-6)................1261
    S4D95LWE-5 RIGHT SIDE VIEW (WA80HH-6)................1262
    S4D95LWE-5 FRONT VIEW (WA80HH-6)................1263
    S4D95LWE-5 REAR VIEW (WA80HH-6)................1264
    DIMENSION TABLE................1265
    Engine performance curve................1266
    4D95LWE-5 [Applicable machine: WA65-HH-6]................1266
    4D95LWE-5 [Applicable machine: WA70-HH-6]................1267
    4D95LWE-5 [Applicable machine: WA80-HH-6]................1268
    Weight table................1269
  11 STRUCTURE AND FUNCTION................1270
    General structure................1271
    EXHAUST SYSTEM................1275
      Turbocharger................1275
      TD04L................1275
        Outline of waste gate valve................1276
    ENGINE BODY................1277
      Cylinder head................1277
        4D95LWE-5................1277
        Cylinder head................1278
        Head cover................1278
        S4D95LWE-5................1279
        Cylinder head................1280
        Head cover................1280
      Cylinder block................1281
      Main moving parts................1283
      Timing gear................1285
      WITHOUT FRONT PTO TYPE (HELICAL GEAR)................1285
        Front oil seal................1286
      Valve system................1287
      Flywheel and flywheel housing................1289
      WITHOUT REAR PTO TYPE................1289
    LUBRICATION SYSTEM................1291
      Lubrication system chart................1291
      Oil pump................1292
        Specifications................1292
        Oil pump................1292
        Regulator valve................1292
      Oil filter................1293
        Relief valve................1293
    FUEL SYSTEM................1294
      Fuel system chart................1294
      Fuel injection pump................1295
      Fuel injection nozzle................1297
      For direct fuel injection type................1297
      For swirl chamber type................1297
        Fuel injection nozzle................1297
    COOLING STSTEM................1298
      Cooling system chart................1298
      Thermostat and fan drive................1299
      THERMOSTAT (WITHOUT JIGGLE VALVE)................1301
    ELECTRICAL SYSTEM................1302
      Starting and charging system electrical circuit diagram................1302
      Alternator................1303
      ALTERNATOR WITH BUILT-IN REGULATOR (Open type, 90A)................1303
      Starting motor................1305
        For 2.2 kW................1305
      Engine starting device................1306
      GLOW PLUG (METAL 2-WIRE TYPE GLOW PLUG)................1306
        1. Connector (round 8-pin), (Short 8-pin)................1307
        2. Lead wire................1307
        3. Case................1307
        4. Bracket................1307
        5. Label................1307
        1. Water temperature sensor................1307
        1. Glow relay................1307
        2. Lead wire................1307
        3. Connector (round 2-in)................1307
  12 TESTING AND ADJUSTING................1308
    Performance test................1309
    Run-in standard................1309
    Performance test criteria................1311
    Testing and adjusting data................1313
    Testing and adjusting tools list................1314
    Intake and exhaust system................1315
    Adjusting valve clearance................1315
    Engine body................1317
    Measuring compression pressure................1317
      Measurement procedure................1317
    Fuel system................1318
    Adjusting fuel injection pressure (Cracking pressure)................1318
    Shim data for adjusting injection pressure................1319
    Testing and adjusting fuel injection timing................1320
    Table of injection pumps using plunger with stepped lead................1325
    Adjusting fuel injection rate................1326
    Governor adjustment standard................1327
    Troubleshooting................1330
    Method of using troubleshooting charts................1331
    Points on troubleshooting................1335
    S-1 Starting performance is poor (Starting always takes time)................1336
    S-2 Engine does not start................1337
      1) Engine does not turn................1337
      2) Engine turns but no exhaust gas comes out (Fuel is not being injected)................1338
      3) Exhaust gas comes out but engine does not start (Fuel is being injected)................1339
    S-3 Engine does not pick up smoothly (Follow-up is poor)................1340
    S-4 Engine stops during operations................1341
    S-5 Engine does not rotate smoothly................1342
    S-6 Engine lacks output (no power)................1343
    S-7 Exhaust gas is black (incomplete combustion)................1344
    S-8 Oil consumption is excessive (or exhaust gas is blue)................1345
    S-9 Oil becomes contaminated quickly................1346
    S-10 Fuel consumption is excessive................1347
    S-11 Oil is in coolant, or coolant spurts back, or coolant level goes down................1348
    S-12 Oil pressure lamp lights up (drop in oil pressure)................1349
    S-13 Oil level rises................1350
    S-14 Coolant temperature becomes too high (overheating)................1351
    S-15 Abnormal noise is made................1352
    S-16 Vibration is excessive................1353
  13 DISASSEMLY AND ASSEMBLY................1354
    General disassembly................1355
      Special tools................1355
    General assembly................1367
      Special tools................1367
  14 MAINTENANCE STANDARD................1386
    Turbocharger................1387
    Cylinder head................1389
    Valve, valve guide................1391
    Rocker arm shaft, push rod and tappet................1392
    Cylinder block................1393
    Cylinder................1395
    Crankshaft................1396
    Camshaft................1397
    Timing gear (Helical gear)................1399
    Flywheel and flywheel housing................1400
    Piston, piston ring and piston pin................1401
    Connecting rod................1403
    Regulator valve................1405
    Water pump and thermostat................1406
  15 REPAIR AND REPLACEMENT OF PARTS................1408
    Grinding cylinder head mounting surface................1409
    Replacing valve guide................1410
      Special tools................1410
    Grinding valve................1411
      Special tool................1411
    Replacing camshaft bushing................1412
      Special tools................1412
    Replacing crankshaft gear................1414
    Testing and adjusting fuel injection timing................1415
    Replacing flywheel ring gear................1416
    Procedure for pressure test................1417
      Special tools................1417
    Cylinder liner................1418
    (special restoration part)................1418
      Cylinder liner................1418
    Machining drawing for cylinder block bore................1419
    Additional machining of cam journal................1420
    Grinding crankshaft................1421
      Applicable crankshaft................1421
    Replacing connecting rod small end bushing................1422
      Special tools................1422

Complete service repair manual with Electrical Wiring Diagrams for Komatsu 95 Series Diesel Engines, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

Komatsu 95 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.

SEBE61460114 - 95 Series Diesel Engine Shop Manual.pdf
SEBM018803 - 95-2 Series Diesel Engine Shop Manual.pdf
SEBM031001 - 95-3 Series Diesel Engines Shop Manual.pdf
SEN04408-00 - 95 Series Diesel Engine Shop Manual.pdf

PRODUCT DETAILS:
Total Pages: 1,422 pages
File Format: PDF
Language: English

MAIN SECTIONS
01 GENERAL ....... 01-1
11 STRUCTURE AND FUNCTION .... 11-1
12 TESTING AND ADJUSTING ..... 12-1
13 DISASSEMBLY AND ASSEMBLY .... 13-1
14 MAINTENANCE STANDARD ..... 14-1
15 REPAIR AND REPLACEMENT OF PARTS ... 15-1

SEBE61460114 - 95 Series Diesel Engine Shop Manual................2
  CONTENTS................3
  01 GENERAL ................28
    GENERAL VIEW ................29
    SPECIFICATIONS ................31
    GENERAL ASSEMBLY DRAWING ................53
    ENGINE PERFORMANCE CURVE ................95
    WEIGHT TABLE................155
  11 STRUCTURE AND FUNCTION ................158
    GENERAL STRUCTURE ................159
    INTAKE AND EXHAUST SYSTEM ................170
      INTAKE AND EXHAUST SYSTEM................170
      FTG AIR CLEANER................186
      TURBOCHARGER................190
      AFTER-COOLER................197
    ENGINE BODY................199
      CYLINDER HEAD................199
      VALVE SYSTEM................219
      CYLINDER BLOCK................227
      CYLINDER LINER................233
      MAIN CIRCULATION SYSTEM................235
      TIMING GEAR................253
      FLYWHEEL AND FLYWHEEL HOUSING................259
    LUBRICATION SYSTEM................264
      LUBRICATION SYSTEM CHART................264
      OIL PUMP ................270
      OIL FILTER ................271
      OIL COOLER ................273
    FUEL SYSTEM ................275
      FUEL SYSTEM CHART ................275
      FUEL INJECTION PUMP ................287
      GOVERNOR................317
      FEED PUMP................321
      FUEL INJECTION NOZZLE ................323
      FUEL CUT SOLENOID ................326
      ENGINE STOP MOTOR ................329
      FUEL FILTER ................334
      WATER SEPARATOR ................335
    COOLING SYSTEM ................336
      COOLING SYSTEM CHART ................336
      WATER PUMP ................339
      CORROSION RESISTOR (OPTION) ................342
      THERMOSTAT  AND FAN DRIVE ................343
    ELECTRICAL SYSTEM................353
      ALTERNATOR................353
      STARTING MOTOR ................362
      ELECTRICAL INTAKE AIR HEATER ................368
    ACCESSORY................373
      AIR COMPRESSOR................373
  12 TESTING AND ADJUSTING................376
    INTAKE AND EXHAUST SYSTEM................377
      ADJUSTING VALVE CLEARANCE................377
      MEASURING EXHAUST GAS COLOR................379
    ENGINE BODY................380
      MEASURING COMPRESSION PRESSURE................380
      MEASURING BLOW-BY PRESSURE................381
      ADJUSTING ENGINE SPEED SENSOR................382
    FUEL SYSTEM................383
      CHECKING AND ADJUSTING FUEL INJECTION TIMING................383
      ADJUSTING GOVERNOR................393
      TESTING AND ADJUSTING FUEL CUT SOLENOID................396
      PROCEDURE FOR ADJUSTING ENGINE STOP MOTOR CABLE................401
      ADJUSTING FUEL INJECTION PRESSURE................403
    LUBRICATION SYSTEM................406
      MEASURING OIL PRESSURE................406
      MEASURING OIL TEMPERATURE................407
    COOLING SYSTEM................408
      MEASURING WATER TEMPERATURE................408
      TESTING AND ADJUSTING FAN BELT TENSION................409
    FUEL INJECTION PUMP CALIBRATION DATA................410
    PERFORMANCE TEST................529
      RUN-IN STANDARD................529
      PERFORMANCE TEST CRITERIA................538
      TESTING AND ADJUSTING TOOL LIST................559
      TESTING AND ADJUSTING DATA................560
    TROUBLESHOOTING................583
      METHOD OF USING TROUBLESHOOTING TABLE................584
      POINTS TO REMEMBER WHEN TROUBLESHOOTING................588
      S-1 Starting performance is poor (Starting always takes time) ................589
      S-2 Engine does not start................590
        (1) Engine does not turn................590
        (2) Engine turns but no exhaust gas comes out (Fuel is not being injected)................591
        (3) Exhaust gas comes out but engine does not start (Fuel is being injected)................592
      S-3 Engine does not pick up smoothly (Follow-up is poor) ................593
      S-4 Engine stops during operations ................594
      S-5 Engine does not rotate smoothly ................595
      S-6 Engine lacks output (no power) ................596
      S-7 Exhaust gas is black (incomplete combustion) ................597
      S-8 Oil consumption is excessive (or exhaust gas is blue)................598
      S-9 Oil becomes contaminated quickly ................599
      S-10 Fuel consumption is excessive ................600
      S-11 Oil is in cooling water, or water spurts back, or water level ................601
      S-12 Oil pressure lamp lights up (drop in oil pressure) ................602
      S-13 Oil level rises................603
      S-14 Water temperature becomes too high (overheating) ................604
      S-15 Abnormal noise is made................605
      S-16 Vibration is excessive................606
      S-17 Diagnosis of electronical governor by diagnosis display (electronical governor made by ZEXEL)................607
  13 DISASSEMBLY AND ASSEMBLY................623
    3D95S-W-1................624
      GENERAL DISASSEMBLY................625
      GENERAL ASSEMBLY ................632
    4D95S-1................645
      GENERAL DISASSEMBLY................646
      GENERAL ASSEMBLY ................656
    4D95L SERIES................672
      GENERAL DISASSEMBLY................672
      GENERAL ASSEMBLY................686
    6D95L SERIES................708
      GENERAL DISASSEMBLY................708
      GENERAL ASSEMBLY................722
    DISASSEMBLY AND ASSEMBLY OF AIR COMPRESSOR................746
  14 MAINTENANCE STANDARD ................753
    TURBOCHARGER ................754
    CYLINDER HEAD ................757
    VALVE, VALVE GUIDE................762
    ROCKER ARM SHAFT, PUSH ROD AND TAPPET................765
    CYLINDER BLOCK ................766
    CRANKSHAFT ................768
    CAMSHAFT ................772
    TIMING GEAR (HELICAL GEAR) ................778
    FLYWHEEL AND FLYWHEEL HOUSING ................783
    PISTON, PISTON RING AND PISTON PIN................784
    CONNECTING ROD ................793
    OIL PUMP ................794
    REGULATOR VALVE ................796
    WATER PUMP, THERMOSTAT ................797
    FUEL SYSTEM ................800
  15 REPAIR AND REPLACEMENT ................803
    CYLINDER HEAD SECTION................805
      GRINDING CYLINDER HEAD  MOUNTING  SURFACE ................805
      REPLACING VALVE SEAT INSERT................806
      REPLACING VALVE GUIDE ................810
      GRINDING VALVE ................811
    CYLINDER BLOCK SECTION................812
      REPLACING CAM BUSHING ................812
      REPLACING GEARS................814
      PROCEDURE FOR PRESSURE TEST ................816
      CYLINDER LINER (SPECIAL RESTORATION PART) ................817
      MACHINING DRAWING FOR CYLINDER BLOCK BORE ................818
      ADDITIONAL MACHINING OF CAM JOURNAL ................819
      GRINDING CRANKSHAFT ................820
SEBM018803 - 95-2 Series Diesel Engine Shop Manual................822
  COVER................822
  CONTENTS................823
  SAFETY................826
    SAFETY NOTICE................826
  FOREWORD................828
    GENERAL................828
    HOW TO READ THE SHOP MANUAL................829
    HOISTING INSTRUCTIONS................830
    METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER................831
    COATING MATERIALS................833
    STANDARD TIGHTENING TORQUE................835
    ELECTRIC WIRE CODE................838
    CONVERSION TABLE................839
    UNITS................845
  01 GENERAL................846
    APPLICABLE MACHINE................847
    SPECIFICATIONS................848
    WEIGHT TABLE................850
    OVERALL DRAWING ................851
    ENGINE PERFORMANCE CURVE................854
  11 STRUCTURE AND FUNCTION................857
    GENERAL STRUCTURE................858
      GENERAL STRUCTURE................858
    INTAKE AND EXHAUST SYSTEM ................860
      INTAKE AND EXHAUST SYSTEM ................860
      AIR CLEANER................862
    ENGINE BODY................864
      CYLINDER HEAD................864
      CYLINDER BLOCK................866
      MAIN CIRCULATION SYSTEM................868
      TIMING GEAR................870
      VALVE SYSTEM ................872
      FLYWHEEL AND FLYWHEEL HOUSING................874
    LUBRICATION SYSTEM ................876
      LUBRICATION SYSTEM CHART................876
      OIL PUMP................877
      OIL FILTER ................878
      OIL FILTER MOUNT................879
    FUEL SYSTEM ................881
      FUEL SYSTEM CHART................881
      FUEL INJECTION PUMP................882
      FUEL INJECTION NOZZLE................884
      FUEL FILTER................885
      ENGINE CUT SOLENOID................886
    COOLING SYSTEM................887
      COOLING SYSTEM CHART................887
      WATER PUMP................888
      FAN DRIVE AND THERMOSTAT................889
    ELECTRICAL SYSTEM ................892
      STARTING AND CHARGING SYSTEM ELECTRICAL CIRCUIT DIAGRAM................892
      ALTERNATOR................893
      STARTING MOTOR................894
      ENGINE STARTING DEVICE................895
  12 TESTING AND ADJUSTING................896
    TESTING AND ADJUSTING................897
      ADJUSTING VALVLE CLEARANCE................897
      MEASURING COMPRESSION PRESSURE................899
      ADJUSTING FUEL INJECTION PRESSURE................900
      TESTING AND ADJUSTING FUEL INJECTION TIMING................901
      ADJUSTING FUEL CUT SOLENOID................905
    FUEL INJECTION PUMP CALIBRATION DATA................908
    PERFORMANCE TEST ................911
      RUN-IN STANDARD................911
      PERFORMANCE TEST CRITERIA ................912
    TROUBLESHOOTING................914
      METHOD OF USING TROUBLESHOOTING CHARTS................915
      POINTS TO REMEMBER WHEN TROUBLESHOOTING................919
      S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)................920
      S-2 ENGINE DOES NOT START................921
        (1) ENGINE DOES NOT TURN................921
        (2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED)................922
        (3) EXHAUST SMOKE COMES OUT, BUT ENGINE DOES NOT START (FUEL IS NOT BEING INJECTED)................923
      S-3 ENGINE DOES NOT PICK UP SMOOTHLY................924
      S-4 ENGINE STOPS DURING OPERATIONS................925
      S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)................926
      S-6 ENGINE LACK OUTPUT (NO POWER)................927
      S-7 EXHAUST GAS IS BLACK................928
      S-8 OIL CONSUMPTION IS EXCESSIVE, OR EXHAUST GAS IS BLUE................929
      S-9 OIL BECOMES CONTAMINATED QUICKLY................930
      S-10 FUEL CONSUMPTION IS EXCESSIVE................931
      S-11 OIL IS IN COOLING WATER ................932
      S-12 OIL PRESSURE CAUTION LAMP LIGHTS UPS (DROP IN OIL PRESSURE)................933
      S-13 OIL LEVEL RISES (WATER, FUEL IN OIL )................934
      S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)................935
      S-15 ABNORMAL NOISE IS MADE................936
      S-16 VIBRATION IS EXCESSIVE................937
    TESTING AND ADJUSTING TOOL LIST................938
    TESTING AND ADJUSTING DATA................939
  13 DISASSEMBLY AND ASSEMBLY................941
    SPECIAL TOOL LIST................942
    OVERALL DISASSEMBLY OF 4D95LC-2................943
      PREPARATORY WORK................944
      1. ALTERNATOR, FAN PULLEY................944
      2. STARTING MOTOR, ENGINE STOP SOLENOID, FUEL AND OIL FILTERS, DIPSTICK................945
      3. WATER PUMP................945
      4. FUEL INJECTION TUBE, GLOW PLUG................945
      5. INJECTION NOZZLE................945
      6. FUEL INJECTION PUMP................946
      7. INTAKE MANIFOLD................946
      8. EXHAUST MANIFOLD................946
      9. HEAD COVER................946
      10. ROCKER ARM................947
      11. PUSH ROD, CYLINDER HEAD MOUNTING BOLT................947
      12. CYLINDER HEAD COVER................947
      13. PTO SHAFT................948
      14. OIL PAN................949
      15. OIL SUCTION PIPE................949
      16. CRANKSHAFT PULLEY................949
      17. GEAR CASE COVER................949
      18. OIL PUMP, IDLER GEAR................950
      19. CAMSHAFT ASSEMBLY................950
      20. FLYWHEEL................950
      21. FLYWHEEL HOUSING................951
      22. PISTION, CONNECTING ROD ASSEMBLY................951
      23. MAIN CAP................953
      24. CRANKSHAFT................954
      25. TAPPET................954
      26.CYLINDER BLOCK ASSEMBLY................954
    OVERALL ASSEMBLY................955
      1. CYLINDER BLOCK ASSEMBLY................955
      2. TAPPET................955
      3. CRANKSHAFT................955
      4. MAIN CAP................956
      5. FLYWHEEL HOUSING................959
      6. FLYWHEEL................960
      7. CAMSHAFT ASSEMBLY................960
      8. OIL PUMP, IDLER GEAR................961
      9. GEAR CASE COVER................962
      10. CRANKSHAFT PULLEY................962
      11. OIL SUCTION PIPE................962
      12. OIL PAN................963
      13. PTO SHAFT................963
      14. FUEL INJECTION PUMP................963
      15. CYLINDER HEAD ASSEMBLY................964
      16. ADJUSTMENT OF VALVE CLEARANCE................966
      17. HEAD COVER................967
      18. EXHAUST MANIFOLD................967
      19. INTAKE MANIFOLD................967
      20. INJECTION NOZZLE................967
      21. FUEL INJECTION TUBE, GLOW PLUG................968
      22. WATER PUMP................968
      23. STARTING MOTOR. ENGINE STOP SOLENOID, FUEL AND OIL FILTERS, DIPSTICK................968
      24. ALTERNATOR, FAN PULLEY................969
      25. ENGINE ASSEMBLY................969
      26. FAN, EXHAUST PIPE, MUFFLER, ENGINE OIL TUBES, BLOCK, COVER................970
  14 MAINTENANCE STANDARD................971
    CYLINDER HEAD................972
    VALVE AND VALVE GUIDE................973
    ROCKER ARM SHAFT, PUSH ROD AND TAPPET................974
    CYLINDER BLOCK................975
    CYLINDER................976
    CRANKSHAFT................977
    CAMSHAFT................978
    TIMING GEAR................979
    PISTION, PISTON RING AND PISTION PIN................980
    CONNECTING ROD................981
    FLYWHEEL AND FLYWHEEL HOUSING................982
    OIL PUMP................983
    REGULATOR VALVE................984
    WATER PUMP AND THERMOSTAT................985
  15 REPAIR AND REPLACEMENT OF PARTS................986
    CYLINDER HEAD SECTION................987
      GRINDING CYLINDER HEAD MOUNTING SURFACE................987
      REPLACING VALVE GUIDE................988
      GRINDING VALVE................989
    CYLINDER BLOCK SECTION................990
      REPLACING CAMSHAFT BUSHING................990
      REPLACING CRANKSHAFT GEAR................992
      REPLACING CAM GEAR................993
      REPLACING FLYWHEEL RING GEAR................994
      PROCEDURE FOR PRESSURE TEST ................995
      CYLINDER LINER (SPECIAL RESTORATION PART)................996
      MACHINING DRAWING FOR CYLINDER BLOCK BORE................997
      ADDITIONAL MACHINING OF CAM JOURNAL................998
      GRINDING CRANKSHAFT................999
      REPLACING CONNECTING ROD SMALL END BUSHING................1000
SEBM031001 - 95-3 Series Diesel Engines Shop Manual................1002
  SAFETY ................1006
    SAFETY NOTICE ................1006
  FOREWORD ................1008
    GENERAL ................1008
    STANDARD TIGHTENING TORQUE ................1015
    CONVERSION TABLE ................1019
  SPECIFICATIONS ................1031
  OVERALL DRAWING ................1037
  GENERAL STRUCTURE ................1047
  INTAKE AND EXHAUST SYSTEM ................1049
  AIR CLEANER ................1053
  CYLINDER ................1066
  MAIN CIRCULATION SYSTEM ................1067
  CRANKSHAFT ................1071
  CONNECTING ROD ................1075
  TIMING GEAR ................1081
  CAMSHAFT ................1087
  ROCKER ARM SHAFT, PUSH ROD AND TAPPET ................1088
  OIL PUMP ................1091
  OIL FILTER ................1098
  FUEL SYSTEM CHART ................1100
  FUEL INJECTION PUMP ................1103
  COOLING SYSTEM CHART ................1114
  WATER PUMP ................1115
  STARTING AND CHARGING SYSTEM ELECTRICAL CIRCUIT DIAGRAM ................1121
  ADJUSTING VALVE CLEARANCE ................1129
  MEASURING COMPRESSION PRESSURE ................1131
  ADJUSTING FUEL INJECTION PRESSURE ( CRACKING PRESSURE) ................1132
  PERFORMANCE TEST ................1145
  METHOD OF USING TROUBLESHOOTING CHARTS ................1151
  POINTS TO REMEMBER WHEN TROUBLESHOOTING ................1155
  TESTING AND ADJUSTING TOOL LIST ................1174
  SPECIAL TOOL LIST ................1179
  OVERALL DISASSEMBLY, ASSEMBLY ................1180
  DISASSEMBLY ................1181
  ASSEMBLY ................1193
  GRINDING CYLINDER HEAD MOUNTING SURFACE ................1211
  REPLACING VALVE GUIDE ................1212
  GRINDING VALVE ................1213
  REPLACING CAMSHAFT BUSHING ................1214
  REPLACING CRANKSHAFT GEAR ................1216
  REPLACING CAM GEAR ................1217
  REPLACING FLYWHEEL RING GEAR ................1218
  PROCEDURE FOR PRESSURE TEST ................1219
  CYLINDER LINER ( SPECIAL RESTORATION PART) ................1220
  MACHINING DRAWING FOR CYLINDER BLOCK BORE ................1221
  GRINDING CRANKSHAFT ................1223
SEN04408-00 - 95 Series Diesel Engine Shop Manual................1226
  SEN04408-00 WA65-6, WA70-6, WA80-6................1226
  CONTENTS................1227
  SAFETY................1227
  FOREWORD................1229
  01 GENERAL................1248
    General................1249
    General view................1251
    4D95LWE-5................1251
    S4D95LWE-5................1253
    Specifications................1255
    General assembly drawing................1257
    4D95LWE-5 LEFT SIDE VIEW (WA65HH-6)................1257
    4D95LWE-5 RIGHT SIDE VIEW (WA65HH-6)................1258
    4D95LWE-5 FRONT VIEW (WA65HH-6)................1259
    4D95LWE-5 REAR VIEW (WA65HH-6)................1260
    S4D95LWE-5 LEFT SIDE VIEW (WA80HH-6)................1261
    S4D95LWE-5 RIGHT SIDE VIEW (WA80HH-6)................1262
    S4D95LWE-5 FRONT VIEW (WA80HH-6)................1263
    S4D95LWE-5 REAR VIEW (WA80HH-6)................1264
    DIMENSION TABLE................1265
    Engine performance curve................1266
    4D95LWE-5 [Applicable machine: WA65-HH-6]................1266
    4D95LWE-5 [Applicable machine: WA70-HH-6]................1267
    4D95LWE-5 [Applicable machine: WA80-HH-6]................1268
    Weight table................1269
  11 STRUCTURE AND FUNCTION................1270
    General structure................1271
    EXHAUST SYSTEM................1275
      Turbocharger................1275
      TD04L................1275
        Outline of waste gate valve................1276
    ENGINE BODY................1277
      Cylinder head................1277
        4D95LWE-5................1277
        Cylinder head................1278
        Head cover................1278
        S4D95LWE-5................1279
        Cylinder head................1280
        Head cover................1280
      Cylinder block................1281
      Main moving parts................1283
      Timing gear................1285
      WITHOUT FRONT PTO TYPE (HELICAL GEAR)................1285
        Front oil seal................1286
      Valve system................1287
      Flywheel and flywheel housing................1289
      WITHOUT REAR PTO TYPE................1289
    LUBRICATION SYSTEM................1291
      Lubrication system chart................1291
      Oil pump................1292
        Specifications................1292
        Oil pump................1292
        Regulator valve................1292
      Oil filter................1293
        Relief valve................1293
    FUEL SYSTEM................1294
      Fuel system chart................1294
      Fuel injection pump................1295
      Fuel injection nozzle................1297
      For direct fuel injection type................1297
      For swirl chamber type................1297
        Fuel injection nozzle................1297
    COOLING STSTEM................1298
      Cooling system chart................1298
      Thermostat and fan drive................1299
      THERMOSTAT (WITHOUT JIGGLE VALVE)................1301
    ELECTRICAL SYSTEM................1302
      Starting and charging system electrical circuit diagram................1302
      Alternator................1303
      ALTERNATOR WITH BUILT-IN REGULATOR (Open type, 90A)................1303
      Starting motor................1305
        For 2.2 kW................1305
      Engine starting device................1306
      GLOW PLUG (METAL 2-WIRE TYPE GLOW PLUG)................1306
        1. Connector (round 8-pin), (Short 8-pin)................1307
        2. Lead wire................1307
        3. Case................1307
        4. Bracket................1307
        5. Label................1307
        1. Water temperature sensor................1307
        1. Glow relay................1307
        2. Lead wire................1307
        3. Connector (round 2-in)................1307
  12 TESTING AND ADJUSTING................1308
    Performance test................1309
    Run-in standard................1309
    Performance test criteria................1311
    Testing and adjusting data................1313
    Testing and adjusting tools list................1314
    Intake and exhaust system................1315
    Adjusting valve clearance................1315
    Engine body................1317
    Measuring compression pressure................1317
      Measurement procedure................1317
    Fuel system................1318
    Adjusting fuel injection pressure (Cracking pressure)................1318
    Shim data for adjusting injection pressure................1319
    Testing and adjusting fuel injection timing................1320
    Table of injection pumps using plunger with stepped lead................1325
    Adjusting fuel injection rate................1326
    Governor adjustment standard................1327
    Troubleshooting................1330
    Method of using troubleshooting charts................1331
    Points on troubleshooting................1335
    S-1 Starting performance is poor (Starting always takes time)................1336
    S-2 Engine does not start................1337
      1) Engine does not turn................1337
      2) Engine turns but no exhaust gas comes out (Fuel is not being injected)................1338
      3) Exhaust gas comes out but engine does not start (Fuel is being injected)................1339
    S-3 Engine does not pick up smoothly (Follow-up is poor)................1340
    S-4 Engine stops during operations................1341
    S-5 Engine does not rotate smoothly................1342
    S-6 Engine lacks output (no power)................1343
    S-7 Exhaust gas is black (incomplete combustion)................1344
    S-8 Oil consumption is excessive (or exhaust gas is blue)................1345
    S-9 Oil becomes contaminated quickly................1346
    S-10 Fuel consumption is excessive................1347
    S-11 Oil is in coolant, or coolant spurts back, or coolant level goes down................1348
    S-12 Oil pressure lamp lights up (drop in oil pressure)................1349
    S-13 Oil level rises................1350
    S-14 Coolant temperature becomes too high (overheating)................1351
    S-15 Abnormal noise is made................1352
    S-16 Vibration is excessive................1353
  13 DISASSEMLY AND ASSEMBLY................1354
    General disassembly................1355
      Special tools................1355
    General assembly................1367
      Special tools................1367
  14 MAINTENANCE STANDARD................1386
    Turbocharger................1387
    Cylinder head................1389
    Valve, valve guide................1391
    Rocker arm shaft, push rod and tappet................1392
    Cylinder block................1393
    Cylinder................1395
    Crankshaft................1396
    Camshaft................1397
    Timing gear (Helical gear)................1399
    Flywheel and flywheel housing................1400
    Piston, piston ring and piston pin................1401
    Connecting rod................1403
    Regulator valve................1405
    Water pump and thermostat................1406
  15 REPAIR AND REPLACEMENT OF PARTS................1408
    Grinding cylinder head mounting surface................1409
    Replacing valve guide................1410
      Special tools................1410
    Grinding valve................1411
      Special tool................1411
    Replacing camshaft bushing................1412
      Special tools................1412
    Replacing crankshaft gear................1414
    Testing and adjusting fuel injection timing................1415
    Replacing flywheel ring gear................1416
    Procedure for pressure test................1417
      Special tools................1417
    Cylinder liner................1418
    (special restoration part)................1418
      Cylinder liner................1418
    Machining drawing for cylinder block bore................1419
    Additional machining of cam journal................1420
    Grinding crankshaft................1421
      Applicable crankshaft................1421
    Replacing connecting rod small end bushing................1422
      Special tools................1422

Komatsu 95 Series Diesel Engine Repair Service Manuals

Komatsu 95 Series Diesel Engine Repair Service Manuals