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

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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

DESCRIPTION:

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

FOREWORD
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.

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 PUMP102
BOOST COMPENSATOR106
FUEL INJECTION NOZZLE108
FUEL FILTER109
FUEL CUT SOLENOID112
COOLING SYSTEM CHART113
WATER PUMP114
FAN DRIVE AND THERMOSTAT116
STARTING AND CHARGING SYSTEM ELECTRICAL CIRCUIT DIAGRAM120
ALTERNATOR123
STARTING MOTOR124
ENGINE STARTING DEVICE125
12 TESTING AND ADJUSTING127
ADJUSTING VALVE CLEARANCE128
MEASURING COMPRESSION PRESSURE130
ADJUSTING FUEL INJECTION PRESSURE (CRACKING PRESSURE)131
TESTING AND ADJUSTING FUEL INJECTION TIMING132
ADJUSTING FUEL CUT SOLENOID136
FUEL INJECTION PUMP CALIBRATION DATA140
PERFORMANCE TEST144
PERFORMANCE TEST CRITERIA146
TROUBLESHOOTING149
METHOD OF USING TROUBLESHOOTING CHARTS150
POINTS TO REMEMBER WHEN TROUBLESHOOTING154
S-1 Starting performance is poor (starting always takes time)155
S-2 Engine does not start156
S-3 Engine does not pick up smoothly (follow-up is poor)159
S-4 Engine stops during operations160
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 blue164
S-9 Oil becomes contaminated quickly165
S-10 Fuel consumption is excessive166
S-11 Oil is in cooling water, or water spurts back, or water level goes down167
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 made171
S-16 Vibration is excessive172
TESTING AND ADJUSTING TOOL LIST173
TESTING AND ADJUSTING DATA174
13 DISASSEMBLY AND ASSEMBLY177
SPECIAL TOOL LIST178
OVERALL DISASSEMBLY, ASSEMBLY179
DISASSEMBLY180
ASSEMBLY192
15 REPAIR AND REPLACEMENT OF PARTS209
GRINDING CYLINDER HEAD MOUNTING SURFACE210
REPLACING VALVE GUIDE211
GRINDING VALVE212
REPLACING CAMSHAFT BUSHING213
REPLACING CRANKSHAFT GEAR215
REPLACING CAM GEAR216
REPLACING FLYWHEEL RING GEAR217
PROCEDURE FOR PRESSURE TEST218
CYLINDER LINER (SPECIAL RESTORATION PART)219
MACHINING DRAWING FOR CYLINDER BLOCK BORE220
ADDITIONAL MACHINING OF CAM JOURNAL221
GRINDING CRANKSHAFT222
REPLACING CONNECTING ROD SMALL END BUSHING223

IMAGES PREVIEW OF THE MANUAL:

S.M 15/12/24