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KOMATSU 95-3 SERIES DIESEL ENGINE SHOP MANUAL SEBM031002 – PDF DOWNLOAD
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Description
KOMATSU 95-3 SERIES DIESEL ENGINE SHOP MANUAL SEBM031002 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU 95-3 SERIES DIESEL ENGINE SHOP MANUAL SEBM031002 – PDF DOWNLOAD
Language : English
Pages : 224
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
KOMATSU 95-3 SERIES DIESEL ENGINE SHOP MANUAL SEBM031002 – PDF DOWNLOAD
Cover................................................................................... 1 01 GENERAL.............................................................................. 25 GENERAL............................................................................. 26 SPECIFICATIONS...................................................................... 30 WEIGHT TABLE........................................................................ 35 OVERALL DRAWING..................................................................... 36 ENGINE PERFORMANCE CURVE............................................................ 42 11 STRUCTURE, FUNCTION ANDMAINTENANCE STANDARD.......................................... 45 GENERAL STRUCTURE................................................................... 46 INTAKE AND EXHAUST SYSTEM........................................................... 48 AIR CLEANER......................................................................... 52 TURBOCHARGER........................................................................ 54 CYLINDER HEAD....................................................................... 58 CYLINDER BLOCK...................................................................... 62 CYLINDER............................................................................ 65 MAIN CIRCULATION SYSTEM............................................................. 66 CRANKSHAFT.......................................................................... 70 PISTON, PISTON RING AND PISTON PIN.................................................. 71 CONNECTING ROD...................................................................... 74 FLYWHEEL AND FLYWHEEL HOUSING....................................................... 76 TIMING GEAR......................................................................... 80 VALVE SYSTEM........................................................................ 84 CAMSHAFT............................................................................ 86 ROCKER ARM SHAFT, PUSH ROD AND TAPPET............................................... 87 VALVE, VALVE GUIDE.................................................................. 88 LUBRICATION SYSTEM CHART............................................................ 89 OIL PUMP............................................................................ 90 REGULATOR VALVE..................................................................... 94 OIL FILTER MOUNT.................................................................... 96 OIL FILTER.......................................................................... 97 FUEL SYSTEM CHART................................................................... 99 FUEL INJECTION PUMP.................................................................102 BOOST COMPENSATOR...................................................................106 FUEL INJECTION NOZZLE...............................................................108 FUEL FILTER.........................................................................109 FUEL CUT SOLENOID...................................................................112 COOLING SYSTEM CHART................................................................113 WATER PUMP..........................................................................114 FAN DRIVE AND THERMOSTAT............................................................116 STARTING AND CHARGING SYSTEM ELECTRICAL CIRCUIT DIAGRAM.............................120 ALTERNATOR..........................................................................123 STARTING MOTOR......................................................................124 ENGINE STARTING DEVICE..............................................................125 12 TESTING AND ADJUSTING................................................................127 ADJUSTING VALVE CLEARANCE...........................................................128 MEASURING COMPRESSION PRESSURE......................................................130 ADJUSTING FUEL INJECTION PRESSURE (CRACKING PRESSURE)...............................131 TESTING AND ADJUSTING FUEL INJECTION TIMING.........................................132 ADJUSTING FUEL CUT SOLENOID.........................................................136 FUEL INJECTION PUMP CALIBRATION DATA................................................140 PERFORMANCE TEST....................................................................144 PERFORMANCE TEST CRITERIA...........................................................146 TROUBLESHOOTING.....................................................................149 METHOD OF USING TROUBLESHOOTING CHARTS..........................................150 POINTS TO REMEMBER WHEN TROUBLESHOOTING.........................................154 S-1 Starting performance is poor (starting always takes time)...................155 S-2 Engine does not start.......................................................156 S-3 Engine does not pick up smoothly (follow-up is poor)........................159 S-4 Engine stops during operations..............................................160 S-5 Engine does not rotate smoothly (hunting)...................................161 S-6 Engine lacks output (no power)..............................................162 S-7 Exhaust smoke is black (incomplete combustion)..............................163 S-8 Oil consumption is excessive or exhaust smoke is blue.......................164 S-9 Oil becomes contaminated quickly............................................165 S-10 Fuel consumption is excessive..............................................166 S-11 Oil is in cooling water, or water spurts back, or water level goes down....167 S-12 Oil pressure caution lamp lights up (drop in oil pressure).................168 S-13 Oil level rises (water, fuel in oil).......................................169 S-14 Water temperature becomes too high (overheating)...........................170 S-15 Abnormal noise is made.....................................................171 S-16 Vibration is excessive.....................................................172 TESTING AND ADJUSTING TOOL LIST.................................................173 TESTING AND ADJUSTING DATA......................................................174 13 DISASSEMBLY AND ASSEMBLY.............................................................177 SPECIAL TOOL LIST...................................................................178 OVERALL DISASSEMBLY, ASSEMBLY.......................................................179 DISASSEMBLY.........................................................................180 ASSEMBLY............................................................................192 15 REPAIR AND REPLACEMENT OF PARTS......................................................209 GRINDING CYLINDER HEAD MOUNTING SURFACE.............................................210 REPLACING VALVE GUIDE...............................................................211 GRINDING VALVE......................................................................212 REPLACING CAMSHAFT BUSHING..........................................................213 REPLACING CRANKSHAFT GEAR...........................................................215 REPLACING CAM GEAR..................................................................216 REPLACING FLYWHEEL RING GEAR........................................................217 PROCEDURE FOR PRESSURE TEST.........................................................218 CYLINDER LINER (SPECIAL RESTORATION PART)...........................................219 MACHINING DRAWING FOR CYLINDER BLOCK BORE...........................................220 ADDITIONAL MACHINING OF CAM JOURNAL.................................................221 GRINDING CRANKSHAFT.................................................................222 REPLACING CONNECTING ROD SMALL END BUSHING..........................................223
DESCRIPTION:
KOMATSU 95-3 SERIES DIESEL ENGINE SHOP MANUAL SEBM031002 – PDF DOWNLOAD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an
accurate understanding of the product and by showing him the correct way to perform repairs and make judgements.
Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service
workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further
divided into the each main group of components.
STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an understanding
of the structure, but also serves as reference material for troubleshooting.
In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance
standards.
TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as adjustments to
be made at completion of the checks and repairs.
Troubleshooting charts correlating “Problems” with “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the procedures for removing, installing, disassembling and assembling each component,
as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.
S.S 12/12/24
