Komatsu 95-3 Series Diesel Engine Shop Manual SEBM031002 – PDF DOWNLOAD

Description

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

2. Outline of engine
• The S4D95LE-3 engine clears strict exhaust gas regulations (USA: EPA regulations for the year 2001, EU:
regulations for the year 2002, Japan: construction equipment regulations for the year 2003). At the same
time, it is a high performance, high efficiency engine which achieves low fuel consumption, low noise,
improved exhaust gas color, and improved acceleration.
This engine has been newly developed to meet various purposes of use as the power unit for construction
equipment and industrial machinery.
• The S4D95LE-3 engine is an in-line, vertical, water-cooled, direct-injection, 4-cycle diesel engine, which
has the following features.
(1) Small-sized and light-weight engine
• Since no liners are used, the distance between the cylinders is shortened by the thickness of the
liners, thus the overall length of the engine is shortened.
• Although the stroke bore ratio is as large as 115 mm : 95 mm, the overall height of the engine is
reduced by reducing the distance between the centers of the large end and small end of the
connecting rod.
• The cylinder head and cylinder block are thinned to reduce their weight, maintaining their strength.
• The weight of each part is reduced to avoid waste by applying reliability analysis technology.
(2) High-performance engine
• Combustion efficiency is improved and exhaust gas is made clean by designing the air intake port
having less air suction resistance and employing the re-entrant combustion chamber.
• Friction loss horsepower is reduced by reducing the weight of the main moving parts and setting the
capacity of the auxiliary devices (water pump and oil pump) properly.
• The weight, noise, and vibration are reduced by adjusting the clearance between each piston and
cylinder properly.
(3) Other items
• Glow plugs which consume less electric power are employed for the starting aid to reduce the load
on the battery.
• Noise is reduced by improving the shape of the piston and applying float mounting of the head
cover.
• Reliability and durability are heightened by the developing technology based on experience and
results of long development of construction machinery and engines for industrial use.

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

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PLEASE NOTE:

• This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
• Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.

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