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Komatsu 95 Series Diesel Engine Shop Manual – PDF DOWNLOAD
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Komatsu 95 Series Diesel Engine Shop Manual
Book Code: SEN04408-00
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Description
Komatsu 95 Series Diesel Engine Shop Manual
FILE DETAILS:
Komatsu 95 Series Diesel Engine Shop Manual
Brands: Komatsu
Equipment Type: Diesel Engine
Manuals Type: Shop Manual
Machine Model: 95 Series Engine
Book Code: SEN04408-00
Language: English
Pages: 198
KOMATSU 95 SERIES DIESEL ENGINE SHOP MANUAL – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu 95 Series Diesel Engine Shop Manual
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 Series Diesel Engine Shop Manual
SEN04408-00 WA65-6, WA70-6, WA80-6..................................................... 1 CONTENTS............................................................................... 2 SAFETY................................................................................. 2 FOREWORD............................................................................... 4 01 GENERAL............................................................................. 23 General............................................................................ 24 General view....................................................................... 26 4D95LWE-5.......................................................................... 26 S4D95LWE-5......................................................................... 28 Specifications..................................................................... 30 General assembly drawing........................................................... 32 4D95LWE-5 LEFT SIDE VIEW (WA65HH-6)................................................ 32 4D95LWE-5 RIGHT SIDE VIEW (WA65HH-6)............................................... 33 4D95LWE-5 FRONT VIEW (WA65HH-6).................................................... 34 4D95LWE-5 REAR VIEW (WA65HH-6)..................................................... 35 S4D95LWE-5 LEFT SIDE VIEW (WA80HH-6)............................................... 36 S4D95LWE-5 RIGHT SIDE VIEW (WA80HH-6).............................................. 37 S4D95LWE-5 FRONT VIEW (WA80HH-6)................................................... 38 S4D95LWE-5 REAR VIEW (WA80HH-6).................................................... 39 DIMENSION TABLE.................................................................... 40 Engine performance curve........................................................... 41 4D95LWE-5 [Applicable machine: WA65-HH-6].......................................... 41 4D95LWE-5 [Applicable machine: WA70-HH-6].......................................... 42 4D95LWE-5 [Applicable machine: WA80-HH-6].......................................... 43 Weight table....................................................................... 44 11 STRUCTURE AND FUNCTION.............................................................. 45 General structure.................................................................. 46 EXHAUST SYSTEM..................................................................... 50 Turbocharger................................................................... 50 TD04L.......................................................................... 50 Outline of waste gate valve................................................ 51 ENGINE BODY........................................................................ 52 Cylinder head.................................................................. 52 4D95LWE-5.................................................................. 52 Cylinder head.............................................................. 53 Head cover................................................................. 53 S4D95LWE-5................................................................. 54 Cylinder head.............................................................. 55 Head cover................................................................. 55 Cylinder block................................................................. 56 Main moving parts.............................................................. 58 Timing gear.................................................................... 60 WITHOUT FRONT PTO TYPE (HELICAL GEAR).......................................... 60 Front oil seal............................................................. 61 Valve system................................................................... 62 Flywheel and flywheel housing.................................................. 64 WITHOUT REAR PTO TYPE.......................................................... 64 LUBRICATION SYSTEM................................................................. 66 Lubrication system chart....................................................... 66 Oil pump....................................................................... 67 Specifications............................................................. 67 Oil pump................................................................... 67 Regulator valve............................................................ 67 Oil filter..................................................................... 68 Relief valve............................................................... 68 FUEL SYSTEM........................................................................ 69 Fuel system chart.............................................................. 69 Fuel injection pump............................................................ 70 Fuel injection nozzle.......................................................... 72 For direct fuel injection type................................................. 72 For swirl chamber type......................................................... 72 Fuel injection nozzle...................................................... 72 COOLING STSTEM..................................................................... 73 Cooling system chart........................................................... 73 Thermostat and fan drive....................................................... 74 THERMOSTAT (WITHOUT JIGGLE VALVE).............................................. 76 ELECTRICAL SYSTEM.................................................................. 77 Starting and charging system electrical circuit diagram........................ 77 Alternator..................................................................... 78 ALTERNATOR WITH BUILT-IN REGULATOR (Open type, 90A)............................ 78 Starting motor................................................................. 80 For 2.2 kW................................................................. 80 Engine starting device......................................................... 81 GLOW PLUG (METAL 2-WIRE TYPE GLOW PLUG)........................................ 81 1. Connector (round 8-pin), (Short 8-pin).................................. 82 2. Lead wire............................................................... 82 3. Case.................................................................... 82 4. Bracket................................................................. 82 5. Label................................................................... 82 1. Water temperature sensor................................................ 82 1. Glow relay.............................................................. 82 2. Lead wire............................................................... 82 3. Connector (round 2-in).................................................. 82 12 TESTING AND ADJUSTING............................................................... 83 Performance test................................................................... 84 Run-in standard.................................................................... 84 Performance test criteria.......................................................... 86 Testing and adjusting data......................................................... 88 Testing and adjusting tools list................................................... 89 Intake and exhaust system.......................................................... 90 Adjusting valve clearance.......................................................... 90 Engine body........................................................................ 92 Measuring compression pressure..................................................... 92 Measurement procedure.......................................................... 92 Fuel system........................................................................ 93 Adjusting fuel injection pressure (Cracking pressure).............................. 93 Shim data for adjusting injection pressure......................................... 94 Testing and adjusting fuel injection timing........................................ 95 Table of injection pumps using plunger with stepped lead...........................100 Adjusting fuel injection rate......................................................101 Governor adjustment standard.......................................................102 Troubleshooting....................................................................105 Method of using troubleshooting charts.............................................106 Points on troubleshooting..........................................................110 S-1 Starting performance is poor (Starting always takes time)......................111 S-2 Engine does not start..........................................................112 1) Engine does not turn........................................................112 2) Engine turns but no exhaust gas comes out (Fuel is not being injected)......113 3) Exhaust gas comes out but engine does not start (Fuel is being injected)....114 S-3 Engine does not pick up smoothly (Follow-up is poor)...........................115 S-4 Engine stops during operations.................................................116 S-5 Engine does not rotate smoothly................................................117 S-6 Engine lacks output (no power).................................................118 S-7 Exhaust gas is black (incomplete combustion)...................................119 S-8 Oil consumption is excessive (or exhaust gas is blue)..........................120 S-9 Oil becomes contaminated quickly...............................................121 S-10 Fuel consumption is excessive.................................................122 S-11 Oil is in coolant, or coolant spurts back, or coolant level goes down.........123 S-12 Oil pressure lamp lights up (drop in oil pressure)............................124 S-13 Oil level rises...............................................................125 S-14 Coolant temperature becomes too high (overheating)............................126 S-15 Abnormal noise is made........................................................127 S-16 Vibration is excessive........................................................128 13 DISASSEMLY AND ASSEMBLY.............................................................129 General disassembly................................................................130 Special tools..................................................................130 General assembly...................................................................142 Special tools..................................................................142 14 MAINTENANCE STANDARD................................................................161 Turbocharger.......................................................................162 Cylinder head......................................................................164 Valve, valve guide.................................................................166 Rocker arm shaft, push rod and tappet..............................................167 Cylinder block.....................................................................168 Cylinder...........................................................................170 Crankshaft.........................................................................171 Camshaft...........................................................................172 Timing gear (Helical gear).........................................................174 Flywheel and flywheel housing......................................................175 Piston, piston ring and piston pin.................................................176 Connecting rod.....................................................................178 Regulator valve....................................................................180 Water pump and thermostat..........................................................181 15 REPAIR AND REPLACEMENT OF PARTS.....................................................183 Grinding cylinder head mounting surface............................................184 Replacing valve guide..............................................................185 Special tools..................................................................185 Grinding valve.....................................................................186 Special tool...................................................................186 Replacing camshaft bushing.........................................................187 Special tools..................................................................187 Replacing crankshaft gear..........................................................189 Testing and adjusting fuel injection timing........................................190 Replacing flywheel ring gear.......................................................191 Procedure for pressure test........................................................192 Special tools..................................................................192 Cylinder liner.....................................................................193 (special restoration part).........................................................193 Cylinder liner.................................................................193 Machining drawing for cylinder block bore..........................................194 Additional machining of cam journal................................................195 Grinding crankshaft................................................................196 Applicable crankshaft..........................................................196 Replacing connecting rod small end bushing.........................................197 Special tools..................................................................197
PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
