Komatsu 95 Series Diesel Engine Shop Manual SEBE61460114

Description

• Model List:
  • 95 Series Diesel Engine

• 1. MAIN MENU
• 2. CONTENTS
• 3. GENERAL
• 3.1. GENERAL VIEW
• 3.2. SPECIFICATIONS
• 3.3. GENERAL ASSEMBLY DRAWING
• 3.4. ENGINE PERFORMANCE CURVE
• 3.5. WEIGHT TABLE
• 4. STRUCTURE AND FUNCTION
• 4.1. GENERAL STRUCTURE
• 4.2. INTAKE AND EXHAUST SYSTEM
• 4.2.1. INTAKE AND EXHAUST SYSTEM
• 4.2.2. FTG AIR CLEANER
• 4.2.3. MAIN CIRCULATION SYSTEM
• 4.2.4. TIMING GEAR
• 4.2.5. FLYWHEEL AND FLYWHEEL HOUSING
• 4.3. LUBRICATION SYSTEM
• 4.3.1. LUBRICATION SYSTEM CHART
• 4.3.2. OIL PUMP
• 4.3.3. OIL FILTER
• 4.3.4. OIL COOLER
• 4.4. FUEL SYSTEM
• 4.4.1. FUEL SYSTEM CHART
• 4.4.2. FUEL INJECTION PUMP
• 4.4.3. GOVERNOR
• 4.4.4. FEED PUMP
• 4.4.5. FUEL INJECTION NOZZLE
• 4.4.6. FUEL CUT SOLENOID
• 4.4.7. ENGINE STOP MOTOR
• 4.4.8. FUEL FILTER
• 4.4.9. WATER SEPARATOR
• 4.5. COOLING SYSTEM
• 4.5.1. COOLING SYSTEM CHART
• 4.5.2. WATER PUMP
• 4.5.3. CORROSION RESISTOR (OPTION)
• 4.5.4. THERMOSTAT AND FAN DRIVE
• 4.6. ELECTRICAL SYSTEM
• 4.6.1. ALTERNATOR
• 4.6.2. STARTING MOTOR
• 4.6.3. ELECTRICAL INTAKE AIR HEATER
• 4.7. ACCESSORY
• 4.7.1. AIR COMPRESSOR
• 5. TESTING AND ADJUSTING
• 5.1. INTAKE AND EXHAUST SYSTEM
• 5.1.1. ADJUSTING VALVE CLEARANCE
• 5.1.2. MEASURING EXHAUST GAS COLOR
• 5.2. ENGINE BODY
• 5.2.1. MEASURING COMPRESSION PRESSURE
• 5.2.2. MEASURING BLOWBY PRESSURE
• 5.2.3. ADJUSTING ENGINE SPEED SENSOR
• 5.3. FUEL SYSTEM
• 5.3.1. CHECKING AND ADJUSTING FUEL INJECTION TIMING
• 5.3.2. ADJUSTING GOVERNOR
• 5.3.3. TESTING AND ADJUSTING FUEL CUT SOLENOID
• 5.3.4. PROCEDURE FOR ADJUSTING ENGINE STOP MOTOR CABLE
• 5.3.5. ADJUSTING FUEL INJECTION PRESSURE
• 5.4. LUBRICATION SYSTEM
• 5.4.1. MEASURING OIL PRESSURE
• 5.4.2. MEASURING OIL TEMPERATURE
• 5.5. COOLING SYSTEM
• 5.5.1. MEASURING WATER TEMPERATURE
• 5.5.2. TESTING AND ADJUSTING FAN BELT TENSION
• 5.6. FUEL INJECTION PUMP CALIBRATION DATA
• 5.7. PERFORMANCE TEST
• 5.7.1. RUNIN STANDARD
• 5.7.2. PERFORMANCE TEST CRITERIA
• 5.7.3. TESTING AND ADJUSTING TOOL LIST
• 5.7.4. TESTING AND ADJUSTING DATA
• 5.8. TROUBLESHOOTING
• 5.8.1. METHOD OF USING TROUBLESHOOTING TABLE
• 5.8.2. POINTS TO REMEMBER WHEN TROUBLESHOOTING
• 5.8.3. S1 Starting performance is poor (Starting always takes time)
• 5.8.4. S2 Engine does not start
• 5.8.4.1. Engine does not turn
• 5.8.4.2. Engine turns but no exhaust gas comes out (Fuel is not being injected)
• 5.8.4.3. Exhaust gas comes out but engine does not start (Fuel is being injected)
• 5.8.5. S3 Engine does not pick up smoothly (Followup is poor)
• 5.8.6. S4 Engine stops during operations
• 5.8.7. S5 Engine does not rotate smoothly
• 5.8.8. S6 Engine lacks output (no power)
• 5.8.9. S7 Exhaust gas is black (incomplete combustion)
• 5.8.10. S8 Oil consumption is excessive (or exhaust gas is blue)
• 5.8.11. S9 Oil becomes contaminated quickly
• 5.8.12. S10 Fuel consumption is excessive
• 5.8.13. S11 Oil is in cooling water, or water spurts back, or water level
• 5.8.14. S12 Oil pressure lamp lights up (drop in oil pressure)
• 5.8.15. S13 Oil level rises
• 5.8.16. S14 Water temperature becomes too high (overheating)
• 5.8.17. S15 Abnormal noise is made
• 5.8.18. S16 Vibration is excessive
• 5.8.19. S17 Diagnosis of electronical governor by diagnosis display (electronical governor made by ZEXEL)
• 6. DISASSEMBLY AND ASSEMBLY
• 6.1.1. GENERAL DISASSEMBLY
• 6.1.2. GENERAL ASSEMBLY
• 6.2.1. GENERAL DISASSEMBLY
• 6.2.2. GENERAL ASSEMBLY
• 6.3. SERIES
• 6.3.1. GENERAL DISASSEMBLY
• 6.3.2. GENERAL ASSEMBLY
• 6.4. SERIES
• 6.4.1. GENERAL DISASSEMBLY
• 6.4.2. GENERAL ASSEMBLY
• 6.5. DISASSEMBLY AND ASSEMBLY OF AIR COMPRESSOR
• 7. MAINTENANCE STANDARD
• 7.1. TURBOCHARGER
• 7.2. CYLINDER HEAD
• 7.3. VALVE, VALVE GUIDE
• 7.4. ROCKER ARM SHAFT, PUSH ROD AND TAPPET
• 7.5. CYLINDER BLOCK
• 7.6. CRANKSHAFT
• 7.7. CAMSHAFT
• 7.8. TIMING GEAR (HELICAL GEAR)
• 7.9. FLYWHEEL AND FLYWHEEL HOUSING
• 7.10. PISTON, PISTON RING AND PISTON PIN
• 7.11. CONNECTING ROD
• 7.12. OIL PUMP
• 7.13. REGULATOR VALVE
• 7.14. WATER PUMP, THERMOSTAT
• 7.15. FUEL SYSTEM
• 8. REPAIR AND REPLACEMENT
• 8.1. CYLINDER HEAD SECTION
• 8.1.1. GRINDING CYLINDER HEAD MOUNTING SURFACE
• 8.1.2. REPLACING VALVE SEAT INSERT
• 8.1.3. REPLACING VALVE GUIDE
• 8.1.4. GRINDING VALVE
• 8.2. CYLINDER BLOCK SECTION
• 8.2.1. REPLACING CAM BUSHING
• 8.2.2. REPLACING GEARS
• 8.2.3. PROCEDURE FOR PRESSURE TEST
• 8.2.4. CYLINDER LINER (SPECIAL RESTORATION PART)
• 8.2.5. MACHINING DRAWING FOR CYLINDER BLOCK BORE
• 8.2.6. ADDITIONAL MACHINING OF CAM JOURNAL
• 8.2.7. GRINDING CRANKSHAFT