Komatsu 95-2 Series Diesel Engine Shop Manual SEBM018803

Description

• Model List:
  • 95-2 Series Diesel Engine

• 0.1. HOW TO READ THE SHOP MANUAL
• 0.2. HOISTING INSTRUCTIONS
• 0.3. METHOD OF DISASSEMBLING, CONNECTING PUSHPULL TYPE COUPLER
• 0.4. COATING MATERIALS
• 0.5. STANDARD TIGHTENING TORQUE
• 0.6. ELECTRIC WIRE CODE
• 0.7. CONVERSION TABLE
• 0.8. UNITS
• 1. GENERAL
• 1.1. APPLICABLE MACHINE
• 1.2. SPECIFICATIONS
• 1.3. WEIGHT TABLE
• 1.4. OVERALL DRAWING
• 1.5. ENGINE PERFORMANCE CURVE
• 2. STRUCTURE AND FUNCTION
• 2.1. GENERAL STRUCTURE
• 2.1.1. GENERAL STRUCTURE
• 2.2. INTAKE AND EXHAUST SYSTEM
• 2.2.1. INTAKE AND EXHAUST SYSTEM
• 2.2.2. AIR CLEANER
• 2.3. ENGINE BODY
• 2.3.1. CYLINDER HEAD
• 2.3.2. CYLINDER BLOCK
• 2.3.3. MAIN CIRCULATION SYSTEM
• 2.3.4. TIMING GEAR
• 2.3.5. VALVE SYSTEM
• 2.3.6. FLYWHEEL AND FLYWHEEL HOUSING
• 2.4. LUBRICATION SYSTEM
• 2.4.1. LUBRICATION SYSTEM CHART
• 2.4.2. OIL PUMP
• 2.4.3. OIL FILTER
• 2.4.4. OIL FILTER MOUNT
• 2.5. FUEL SYSTEM
• 2.5.1. FUEL SYSTEM CHART
• 2.5.2. FUEL INJECTION PUMP
• 2.5.3. FUEL INJECTION NOZZLE
• 2.5.4. FUEL FILTER
• 2.5.5. ENGINE CUT SOLENOID
• 2.6. COOLING SYSTEM
• 2.6.1. COOLING SYSTEM CHART
• 2.6.2. WATER PUMP
• 2.6.3. FAN DRIVE AND THERMOSTAT
• 2.7. ELECTRICAL SYSTEM
• 2.7.1. STARTING AND CHARGING SYSTEM ELECTRICAL CIRCUIT DIAGRAM
• 2.7.2. ALTERNATOR
• 2.7.3. STARTING MOTOR
• 2.7.4. ENGINE STARTING DEVICE
• 3. TESTING AND ADJUSTING
• 3.1. TESTING AND ADJUSTING
• 3.1.1. ADJUSTING VALVLE CLEARANCE
• 3.1.2. MEASURING COMPRESSION PRESSURE
• 3.1.3. ADJUSTING FUEL INJECTION PRESSURE
• 3.1.4. TESTING AND ADJUSTING FUEL INJECTION TIMING
• 3.1.5. ADJUSTING FUEL CUT SOLENOID
• 3.2. FUEL INJECTION PUMP CALIBRATION DATA
• 3.3. PERFORMANCE TEST
• 3.3.1. RUNIN STANDARD
• 3.3.2. PERFORMANCE TEST CRITERIA
• 3.4. TROUBLESHOOTING
• 3.4.1. METHOD OF USING TROUBLESHOOTING CHARTS
• 3.4.2. POINTS TO REMEMBER WHEN TROUBLESHOOTING
• 3.4.3. S1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)
• 3.4.4. S2 ENGINE DOES NOT START
• 3.4.4.1. ENGINE DOES NOT TURN
• 3.4.4.2. ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED)
• 3.4.4.3. EXHAUST SMOKE COMES OUT, BUT ENGINE DOES NOT START (FUEL IS NOT BEING INJECTED)
• 3.4.5. S3 ENGINE DOES NOT PICK UP SMOOTHLY
• 3.4.6. S4 ENGINE STOPS DURING OPERATIONS
• 3.4.7. S5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)
• 3.4.8. S6 ENGINE LACK OUTPUT (NO POWER)
• 3.4.9. S7 EXHAUST GAS IS BLACK
• 3.4.10. S8 OIL CONSUMPTION IS EXCESSIVE, OR EXHAUST GAS IS BLUE
• 3.4.11. S9 OIL BECOMES CONTAMINATED QUICKLY
• 3.4.12. S10 FUEL CONSUMPTION IS EXCESSIVE
• 3.4.13. S11 OIL IS IN COOLING WATER
• 3.4.14. S12 OIL PRESSURE CAUTION LAMP LIGHTS UPS (DROP IN OIL PRESSURE)
• 3.4.15. S13 OIL LEVEL RISES (WATER, FUEL IN OIL )
• 3.4.16. S14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)
• 3.4.17. S15 ABNORMAL NOISE IS MADE
• 3.4.18. S16 VIBRATION IS EXCESSIVE
• 3.5. TESTING AND ADJUSTING TOOL LIST
• 3.6. TESTING AND ADJUSTING DATA
• 4. DISASSEMBLY AND ASSEMBLY
• 4.1. SPECIAL TOOL LIST
• 4.2. OVERALL DISASSEMBLY OF 4D95LC2
• 4.2.1. PREPARATORY WORK
• 4.2.2. ALTERNATOR, FAN PULLEY
• 4.2.3. STARTING MOTOR, ENGINE STOP SOLENOID, FUEL AND OIL FILTERS, DIPSTICK
• 4.2.4. WATER PUMP
• 4.2.5. FUEL INJECTION TUBE, GLOW PLUG
• 4.2.6. INJECTION NOZZLE
• 4.2.7. FUEL INJECTION PUMP
• 4.2.8. INTAKE MANIFOLD
• 4.2.9. EXHAUST MANIFOLD
• 4.2.10. HEAD COVER
• 4.2.11. ROCKER ARM
• 4.2.12. PUSH ROD, CYLINDER HEAD MOUNTING BOLT
• 4.2.13. CYLINDER HEAD COVER
• 4.2.14. PTO SHAFT
• 4.2.15. OIL PAN
• 4.2.16. OIL SUCTION PIPE
• 4.2.17. CRANKSHAFT PULLEY
• 4.2.18. GEAR CASE COVER
• 4.2.19. OIL PUMP, IDLER GEAR
• 4.2.20. CAMSHAFT ASSEMBLY
• 4.2.21. FLYWHEEL
• 4.2.22. FLYWHEEL HOUSING
• 4.2.23. PISTION, CONNECTING ROD ASSEMBLY
• 4.2.24. MAIN CAP
• 4.2.25. CRANKSHAFT
• 4.2.26. TAPPET
• 4.2.27. CYLINDER BLOCK ASSEMBLY
• 4.3. OVERALL ASSEMBLY
• 4.3.1. CYLINDER BLOCK ASSEMBLY
• 4.3.2. TAPPET
• 4.3.3. CRANKSHAFT
• 4.3.4. MAIN CAP
• 4.3.5. FLYWHEEL HOUSING
• 4.3.6. FLYWHEEL
• 4.3.7. CAMSHAFT ASSEMBLY
• 4.3.8. OIL PUMP, IDLER GEAR
• 4.3.9. GEAR CASE COVER
• 4.3.10. CRANKSHAFT PULLEY
• 4.3.11. OIL SUCTION PIPE
• 4.3.12. OIL PAN
• 4.3.13. PTO SHAFT
• 4.3.14. FUEL INJECTION PUMP
• 4.3.15. CYLINDER HEAD ASSEMBLY
• 4.3.16. ADJUSTMENT OF VALVE CLEARANCE
• 4.3.17. HEAD COVER
• 4.3.18. EXHAUST MANIFOLD
• 4.3.19. INTAKE MANIFOLD
• 4.3.20. INJECTION NOZZLE
• 4.3.21. FUEL INJECTION TUBE, GLOW PLUG
• 4.3.22. WATER PUMP
• 4.3.23. STARTING MOTOR. ENGINE STOP SOLENOID, FUEL AND OIL FILTERS, DIPSTICK
• 4.3.24. ALTERNATOR, FAN PULLEY
• 4.3.25. ENGINE ASSEMBLY
• 4.3.26. FAN, EXHAUST PIPE, MUFFLER, ENGINE OIL TUBES, BLOCK, COVER
• 5. MAINTENANCE STANDARD
• 5.1. CYLINDER HEAD
• 5.2. VALVE AND VALVE GUIDE
• 5.3. ROCKER ARM SHAFT, PUSH ROD AND TAPPET
• 5.4. PISTION, PISTON RING AND PISTION PIN
• 5.5. CONNECTING ROD
• 5.6. FLYWHEEL AND FLYWHEEL HOUSING
• 5.7. OIL PUMP
• 5.8. REGULATOR VALVE
• 5.9. WATER PUMP AND THERMOSTAT
• 6. REPAIR AND REPLACEMENT OF PARTS
• 6.1. CYLINDER HEAD SECTION
• 6.1.1. GRINDING CYLINDER HEAD MOUNTING SURFACE
• 6.1.2. REPLACING VALVE GUIDE
• 6.1.3. GRINDING VALVE
• 6.2. CYLINDER BLOCK SECTION
• 6.2.1. REPLACING CAMSHAFT BUSHING
• 6.2.2. REPLACING CRANKSHAFT GEAR
• 6.2.3. REPLACING CAM GEAR
• 6.2.4. REPLACING FLYWHEEL RING GEAR
• 6.2.5. PROCEDURE FOR PRESSURE TEST
• 6.2.6. CYLINDER LINER (SPECIAL RESTORATION PART)
• 6.2.7. MACHINING DRAWING FOR CYLINDER BLOCK BORE
• 6.2.8. ADDITIONAL MACHINING OF CAM JOURNAL
• 6.2.9. GRINDING CRANKSHAFT
• 6.2.10. REPLACING CONNECTING ROD SMALL END BUSHING