Komatsu Engine 95-3 series service manual

Description Komatsu Engine 95-3 series service manual

Komatsu Engine S4D95LE-3, SAA4D95LE-3 series pdf workshop service & repair manual

Technical data, specifications, maintenance, troubleshooting, testing, schematics, adjusting, assembly, disassembly, removal, installation instructions and other information

MANUAL CONTENT:
GENERAL
SPECIFICATIONS
WEIGHT TABLE
OVERALL DRAWING
ENGINE PERFORMANCE CURVE

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
GENERAL STRUCTURE
INTAKE AND EXHAUST SYSTEM
AIR CLEANER
TURBOCHARGER
CYLINDER HEAD
CYLINDER BLOCK
CYLINDER
MAIN CIRCULATION SYSTEM
CRANKSHAFT
PISTON, PISTON RING AND PISTON PIN
CONNECTING ROD
FLYWHEEL AND FLYWHEEL HOUSING
TIMING GEAR
VALVE SYSTEM
CAMSHAFT
ROCKER ARM SHAFT, PUSH ROD AND TAPPET
VALVE, VALVE GUIDE
LUBRICATION SYSTEM CHART
OIL PUMP
REGULATOR VALVE
OIL FILTER MOUNT
OIL FILTER
FUEL SYSTEM CHART
FUEL INJECTION PUMP
BOOST COMPENSATOR
FUEL INJECTION NOZZLE
FUEL FILTER
FUEL CUT SOLENOID
COOLING SYSTEM CHART
WATER PUMP
FAN DRIVE AND THERMOSTAT
STARTING AND CHARGING SYSTEM ELECTRICAL CIRCUIT DIAGRAM
ALTERNATOR
STARTING MOTOR
ENGINE STARTING DEVICE

TESTING AND ADJUSTING
ADJUSTING VALVE CLEARANCE
MEASURING COMPRESSION PRESSURE
ADJUSTING FUEL INJECTION PRESSURE (CRACKING PRESSURE)
TESTING AND ADJUSTING FUEL INJECTION TIMING
ADJUSTING FUEL CUT SOLENOID
FUEL INJECTION PUMP CALIBRATION DATA
PERFORMANCE TEST
PERFORMANCE TEST CRITERIA

TROUBLESHOOTING
METHOD OF USING TROUBLESHOOTING CHARTS
POINTS TO REMEMBER WHEN TROUBLESHOOTING
S-1 Starting performance is poor (starting always takes time)
S-2 Engine does not start
S-3 Engine does not pick up smoothly (follow-up is poor)
S-4 Engine stops during operations
S-5 Engine does not rotate smoothly (hunting)
S-6 Engine lacks output (no power)
S-7 Exhaust smoke is black (incomplete combustion)
S-8 Oil consumption is excessive or exhaust smoke is blue
S-9 Oil becomes contaminated quickly
S-10 Fuel consumption is excessive
S-11 Oil is in cooling water, or water spurts back, or water level goes down
S-12 Oil pressure caution lamp lights up (drop in oil pressure)
S-13 Oil level rises (water, fuel in oil)
S-14 Water temperature becomes too high (overheating)
S-15 Abnormal noise is made
S-16 Vibration is excessive
TESTING AND ADJUSTING TOOL LIST
TESTING AND ADJUSTING DATA

DISASSEMBLY AND ASSEMBLY
SPECIAL TOOL LIST
OVERALL DISASSEMBLY, ASSEMBLY
DISASSEMBLY
Preparatory work
Alternator, fan pulley
Starting motor, engine stop solenoid, fuel and oil filter, dipstick
Water pump
Fuel injection pipe, glow plug
Injection nozzle
Fuel injection pump
Intake manifold
Turbocharger, exhaust manifold assembly
Head cover
Rocker arm
Push rods, cylinder head mounting bolts
Cylinder head cover
PTO shaft
Oil pan
Oil suction pipe
Crankshaft pulley
Gear case cover
Oil pump, idler gear
Camshaft assembly
Flywheel
Flywheel housing
Piston, connecting rod assembly
Main cap
Crankshaft
Tappets
Cylinder block assembly
ASSEMBLY
Cylinder block assembly
Tappets
Crankshaft
Main cap
Flywheel housing
Flywheel
Camshaft
Oil pump, idler gear
Gear case cover
Crankshaft pulley
Oil suction pipe
Oil pan
PTO shaft
Fuel injection pump
Cylinder head
Adjustment of valve clearance
Head cover
Turbocharger, exhaust manifold assembly
Intake manifold
Injection nozzle
Fuel injection pipe, glow plug
Water pump
Starting motor, engine stop solenoid, fuel and engine oil filters, dipstick
Alternator, fan pulley
Engine assembly
Fan, exhaust pipe, muffler, engine oil tube, block, cover

REPAIR AND REPLACEMENT OF PARTS
GRINDING CYLINDER HEAD MOUNTING SURFACE
REPLACING VALVE GUIDE
GRINDING VALVE
REPLACING CAMSHAFT BUSHING
REPLACING CRANKSHAFT GEAR
REPLACING CAM GEAR
REPLACING FLYWHEEL RING GEAR
PROCEDURE FOR PRESSURE TEST
CYLINDER LINER (SPECIAL RESTORATION PART)
MACHINING DRAWING FOR CYLINDER BLOCK BORE
ADDITIONAL MACHINING OF CAM JOURNAL
GRINDING CRANKSHAFT
REPLACING CONNECTING ROD SMALL END BUSHING