This service repair workshop manual PDF download has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the Komatsu 95 Series Diesel Engine 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
APPLICABLE MODELS :
3D95S-W-1
4D95L-1
4D95L-W-1
4D95L-W1
4D95S-1
4D95S-W-1
6D95L-1
S4D95L-1
SA4D95-1
SA6D95L-1
SAA6D95LE-1
3D95S-W-1
Komatsu PC40-5
Komatsu PC40-6
Komatsu PC5OUU-1
Komatsu EC35Z-2
Komatsu EC35ZS-2
Komatsu EC35ZSB-2
4D95S-W-1
Komatsu D2OA,P,S,Q,PL,PLL-6
Komatsu D2lA,P,S,Q,PL-6
Komatsu EC50Z, ZS-5
4D95S-1
Komatsu D2OAG, P, PG, PL, PLL-7 (A)
Komatsu D21A, AG, PG, S, QG-7 (A)
Komatsu WA50-1
4D95L-W-1
Komatsu WA40-1
Komatsu WA70-1
4D95L-1
Komatsu PC60, 60L-3
Komatsu PC6OU-3
Komatsu PC60, 60L-5
Komatsu PC6OU-5
Komatsu PC60, 60L-6
Komatsu PC70-6
Komatsu PC60-6, PC60L-6F (Blade spec.)
Komatsu PC60-7
Komatsu PC60-7 (Blade spec.)
Komatsu PC70-7
Komatsu PC70-7 (Blade spec.)
Komatsu PC75UU-1
Komatsu PC75UU-2
Komatsu PC80-3
Komatsu PC90-1
Komatsu PW60-3
Komatsu EC75Z, ZS-3
Komatsu D21A-7T (Trimming spec.)
S4D95L-1
Komatsu PC100-5
Komatsu PC100-6
Komatsu PC120-5
Komatsu PC1 20-6
Komatsu PC128UU-1
Komatsu JV70DW-1
6D95L-1
Komatsu D31A, P, S, Q-18
Komatsu D31E, P, PL, PLL, S, Q, AM, SM-20(A)
Komatsu D37A-2, D37P-2A
Komatsu D37E-2
Komatsu D37E, P-5 (A)
Komatsu PC100-3
Komatsu PC120-3
Komatsu PC150-3
Komatsu PW150-1
Komatsu WA100-1
Komatsu WR1l-l
Komatsu WA100-1 (Engine No. 46799 and up)
Komatsu WA120-1
Komatsu GD313A-1
Komatsu EG60B, BS-1
S6D95L-1
Komatsu PC150-3, PC150LC-3
Komatsu PC150-5
Komatsu PC180-3
Komatsu PC200-5
Komatsu BR200-1
Komatsu PC200-6
Komatsu PW100-3 (Engine No. up to 36829)
Komatsu PW100-3 (Engine No. 36830 and up)
Komatsu WA180-1
Komatsu WA180-3
Komatsu WA250-3
Komatsu GD461A-1
Komatsu GD510R-1
Komatsu GD511A, R-l
Komatsu GD513A, R-l
Komatsu LW80-1
Komatsu EG85B, BS-1
Komatsu BR200-1
Komatsu DCA85 (at Rated output)
Komatsu QAS85 (at Rated output)
Komatsu DCA85 (at Max output)
Komatsu QAS85 (at Max output)
SA6D95L-1
Komatsu PC220-5, BR300-1 (With air to air aftercooler)
Komatsu PC220-6 (With air to air aftercooler)
SAA6D95LE-1
Komatsu WING100 (LWl00-1, LWl00M-1)
TABLE OF CONTENTS :
01 GENERAL
11 STRUCTURE AND FUNCTION
12 TESTING AND ADJUSTING
13 DISASSEMBLY AND ASSEMBLY
14 MAINTENANCE STANDARD
15 REPAIR AND REPLACEMENT
MANUAL SPECIFICATION :
File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : SEBM028316
Total Pages : 820
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.
This (OEM) Komatsu Shop Manual has detailed illustrations as well as step by step instructions, It is 100 percents complete and intact. they are specifically written for the do-it-yourself-er as well as the experienced mechanic. With step by step instruction & highly detailed exploded pictures & diagrams to show you how to complete the required job correctly & efficiently Using. Provides step-by-step instructions based on the complete dis-assembly of the machine. It is this level of detail, along with hundreds of photos and illustrations, that guide the reader through each service and repair procedure. Complete download comes in pdf format which can work under all PC based windows operating system and Mac also, All pages are printable. Using this repair manual is an inexpensive way to keep your vehicle working properly.
This page sometime can be found use following keyword : service manual, repair manual, workshop manual, technical manual, owner manual, maintenance manual, operating manual, parts manual. Please make sure you read and understand the title of this manual before decided to buy.
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01 GENERAL
-GENERAL VIEW
-SPECIFICATIONS
-GENERAL ASSEMBLY DRAWING
-ENGINE PERFORMANCE CURVE
-WEIGHT TABLE
11 STRUCTURE AND FUNCTION
-GENERAL STRUCTURE
-INTAKE AND EXHAUST SYSTEM
--INTAKE AND EXHAUST SYSTEM
--FTG AIR CLEANER
--TURBOCHARGER
--AFTER-COOLER
-ENGINE BODY
--CYLINDER HEAD
--VALVE SYSTEM
--CYLINDER BLOCK
--CYLINDER LINER
--MAIN CIRCULATION SYSTEM
--TIMING GEAR
--FLYWHEEL AND FLYWHEEL HOUSING
-LUBRICATION SYSTEM
--LUBRICATION SYSTEM CHART
--OIL PUMP
--OIL FILTER
--OIL COOLER
-FUEL SYSTEM
--FUEL SYSTEM CHART
--FUEL INJECTION PUMP
--GOVERNOR
--FEED PUMP
--FUEL INJECTION NOZZLE
--FUEL CUT SOLENOID
--ENGINE STOP MOTOR
--FUEL FILTER
--WATER SEPARATOR
-COOLING SYSTEM
--COOLING SYSTEM CHART
--WATER PUMP
--CORROSION RESISTOR (OPTION)
--THERMOSTAT AND FAN DRIVE
-ELECTRICAL SYSTEM
--ALTERNATOR
--STARTING MOTOR
--ELECTRICAL INTAKE AIR HEATER
-ACCESSORY
--AIR COMPRESSOR
12 TESTING AND ADJUSTING
-INTAKE AND EXHAUST SYSTEM
--ADJUSTING VALVE CLEARANCE
--MEASURING EXHAUST GAS COLOR
-ENGINE BODY
--MEASURING COMPRESSION PRESSURE
--MEASURING BLOW-BY PRESSURE
--ADJUSTING ENGINE SPEED SENSOR
-FUEL SYSTEM
--CHECKING AND ADJUSTING FUEL INJECTION TIMING
--ADJUSTING GOVERNOR
--TESTING AND ADJUSTING FUEL CUT SOLENOID
--PROCEDURE FOR ADJUSTING ENGINE STOP MOTOR CABLE
--ADJUSTING FUEL INJECTION PRESSURE
-LUBRICATION SYSTEM
--MEASURING OIL PRESSURE
--MEASURING OIL TEMPERATURE
-COOLING SYSTEM
--MEASURING WATER TEMPERATURE
--TESTING AND ADJUSTING FAN BELT TENSION
-FUEL INJECTION PUMP CALIBRATION DATA
-PERFORMANCE TEST
--RUN-IN STANDARD
--PERFORMANCE TEST CRITERIA
--TESTING AND ADJUSTING TOOL LIST
--TESTING AND ADJUSTING DATA
-TROUBLESHOOTING
--METHOD OF USING TROUBLESHOOTING TABLE
--POINTS TO REMEMBER WHEN TROUBLESHOOTING
--S-1 Starting performance is poor (Starting always takes time)
--S-2 Engine does not start
---(1) Engine does not turn
---(2) Engine turns but no exhaust gas comes out (Fuel is not being injected)
---(3) Exhaust gas comes out but engine does not start (Fuel is being injected)
--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
--S-6 Engine lacks output (no power)
--S-7 Exhaust gas is black (incomplete combustion)
--S-8 Oil consumption is excessive (or exhaust gas 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
--S-12 Oil pressure lamp lights up (drop in oil pressure)
--S-13 Oil level rises
--S-14 Water temperature becomes too high (overheating)
--S-15 Abnormal noise is made
--S-16 Vibration is excessive
--S-17 Diagnosis of electronical governor by diagnosis display (electronical governor made by ZEXEL)
13 DISASSEMBLY AND ASSEMBLY
-3D95S-W-1
--GENERAL DISASSEMBLY
--GENERAL ASSEMBLY
-4D95S-1
--GENERAL DISASSEMBLY
--GENERAL ASSEMBLY
-4D95L SERIES
--GENERAL DISASSEMBLY
--GENERAL ASSEMBLY
-6D95L SERIES
--GENERAL DISASSEMBLY
--GENERAL ASSEMBLY
-DISASSEMBLY AND ASSEMBLY OF AIR COMPRESSOR
14 MAINTENANCE STANDARD
-TURBOCHARGER
-CYLINDER HEAD
-VALVE, VALVE GUIDE
-ROCKER ARM SHAFT, PUSH ROD AND TAPPET
-CYLINDER BLOCK
-CRANKSHAFT
-CAMSHAFT
-TIMING GEAR (HELICAL GEAR)
-FLYWHEEL AND FLYWHEEL HOUSING
-PISTON, PISTON RING AND PISTON PIN
-CONNECTING ROD
-OIL PUMP
-REGULATOR VALVE
-WATER PUMP, THERMOSTAT
-FUEL SYSTEM
15 REPAIR AND REPLACEMENT
-CYLINDER HEAD SECTION
--GRINDING CYLINDER HEAD MOUNTING SURFACE
--REPLACING VALVE SEAT INSERT
--REPLACING VALVE GUIDE
--GRINDING VALVE
-CYLINDER BLOCK SECTION
--REPLACING CAM BUSHING
--REPLACING GEARS
--PROCEDURE FOR PRESSURE TEST
--CYLINDER LINER (SPECIAL RESTORATION PART)
--MACHINING DRAWING FOR CYLINDER BLOCK BORE
--ADDITIONAL MACHINING OF CAM JOURNAL
--GRINDING CRANKSHAFT
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