PDF Shop Manual Komatsu 95 3 Series Diesel Engine - 3 MB
Perform expert-level repairs and maintenance on your Komatsu 95-3 Series Diesel Engine with this detailed shop manual.
It contains complete specifications, disassembly/assembly procedures, and troubleshooting guides.
This manual is designed for professional mechanics to ensure every repair is done to factory standards.
It is an essential resource for engine overhauls and complex diagnostics.
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--- Page 1 ---
SEBM031001
DIESEL ENGINE
Β© 2004
All Rights Reserved
Printed in Japan 04-04 (01)
00-1
(1)
--- Page 3 ---
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
Type 2 Type 3
1) Hold the mouthpiece of the tightening portion 1) Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end. the hexagonal portion at the male end.
2) Hold in the condition in Step 1), and turn 2) Hold in the condition in Step 1), and push
lever (4) to the right (clockwise). until cover (3) contacts contact surface a of
the hexagonal portion at the male end.
Disassembly
3) Hold in the condition in Steps 1) and 2), and 3) Hold in the condition in Steps 1) and 2), and
pull out whole body (2) to disconnect it. pull out whole body (2) to disconnect it.
β’ Hold the mouthpiece of the tightening portion β’ Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end to con- the hexagonal portion at the male end to con-
nect it. nect it.
Connection
00-9
--- Page 4 ---
FOREWORD CONVERSION TABLE
kgm to ft. lb
1 kgm = 7.233 ft. lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
00-19
--- Page 5 ---
GENERAL SPECIFICATIONS
95-3 SERIES 01-5
--- Page 7 ---
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD INTAKE AND EXHAUST SYSTEM
95-3 SERIES 11-5-2
(1)
--- Page 9 ---
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PISTON, PISTON RING AND PISTON PIN
PISTON, PISTON RING AND PISTON PIN
S4D95LE-3
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit Replace piston
STD 95.00 94.58 (only S size
Outside diameter of piston
1 supplied as
(at right angle to boss) 0.25 O.S. 95.25 95.10 replacement
0.50 O.S. 95.50 95.35 part)
Measuring
No. Standard clearance Clearance limit
2 point
2 Top ring 0.25 β 0.40 2.0 Replace piston
3 Piston ring gap
Second ring or liner
3 0.35 β 0.50 2.0
4 ring
4 Oil ring 0.25 β 0.50 1.5
Measuring Standard Tolerance Standard Clearance
No.
point size Ring Piston clearance limit
5
β0.01 +0.07 0.06 β
5 Top ring 2 0.15
Clearance between piston ring β0.03 +0.05 0.10 Replace piston
6
groove and piston ring ring or piston
Second β0.01 +0.04 0.03 β
6 2 0.20
7 ring β0.03 +0.02 0.07
β0.01 +0.04 0.03 β
7 Oil ring 4 0.15
β0.03 +0.02 0.07
Standard Tolerance Standard Clearance
Clearance between piston and size Shaft Hole clearance limit Replace piston
8
piston pin or piston pin
β0.000 +0.012 0.004 β
30 0.05
β0.006 +0.004 0.018
95-3 SERIES 11-23
(1)
--- Page 10 ---
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TIMING GEAR
SPECIFICATION
Front oil seal
β’ Single lip with dust seal
95-3 SERIES 11-31
--- Page 11 ---
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD OIL PUMP
S4D95LE-3
Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard clear- Clearance limit
size Gear width Body depth ance (End play) (End play)
1 Axial clearance of pump gear
β0.000 β0.070 0.030 β
12 0.10
β0.015 +0.030 0.085
Replace gear
Standard Tolerance Standard Clearance
size Gear width Body O.D. clearance limit
2 Radial clearance of pump gear
+0.115 +0.245 0.045 β
38 0.13
+0.065 +0.205 0.090
Standard Tolerance Standard clearance Clearance or
Interference between pump size Shaft Hole or interference interference limit
3 Replace
drive gear and drive shaft
β0.024 β0.065 0.025 β
13 β
β0.042 β0.086 0.061
Clearance between drive shaft β0.024 +0.018 0.024 β Replace
4 13 β
and cover β0.042 +0.000 0.060 bushing
Interference between pump β0.024 β0.065 0.025 β
5 13 β Replace
gear and drive shaft β0.042 β0.086 0.061
Clearance between drive shaft β0.024 +0.048 0.028 β Replace
6 13 β
and bushing β0.042 +0.004 0.09 bushing
Clearance between driven β0.064 +0.018 0.028 β Replace
7 16 β
shaft and cylinder block +0.046 +0.000 0.064 cylinder block
Clearance between driven β0.110 β0.065 0.024 β Replace shaft
8 13 β
shaft and gear β0.125 β0.086 0.060 or gear
Clearance between drive shaft β0.087 +0.018 0.042 β Replace
9 16 β
bushing hole and cylinder block +0.060 +0.000 0.087 cylinder block
95-3 SERIES 11-41
(1)
--- Page 15 ---
STARTING AND CHARGING SYSTEM
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ELECTRICAL CIRCUIT DIAGRAM
SAA4D95LE-3 STARTING AND CHARGING SYSTEM ELECTRICAL CIRCUIT DIAGRAM
1. Battery 5. Relay
2. Starting motor 6. Electrical intake air heater
3. Alternator 7. Oil pressure caution lamp
4. Starting switch 8. Oil pressure switch
95-3 SERIES 11-60-1
(1)
--- Page 16 ---
TESTING AND ADJUSTING ADJUSTING FUEL INJECTION PRESSURE
ADJUSTING FUEL INJECTION PRESSURE
(CRACKING PRESSURE)
1. Remove retaining cap (1).
2. Remove nozzle (2), spring seat (3), and nozzle
spring (4).
3. Adjust thickness of shim (5) to adjust injection
pressure (cracking pressure).
a Pressure adjustment for 0.1 mm of shim
thickness:
3 Retaining cap:
Approx. 1.47 MPa {15 kg/cm2}
44 Β± 5 Nm {4.5 Β± 0.5 kgm}
SHIM DATA FOR ADJUSTING INJECTION PRESSURE
Unit: mm
Engine Shape Range of shim thickness Range of shim clearance
Inner dia.= 2.1
S4D95LE-3 0.1 β 0.58 0.02
Outer dia.= 7.2
Part No. Thickness (mm) Part No. Thickness (mm)
DK150534-3600 0.100 DK150534-4100 0.520
DK150534-3700 0.200 DK150534-4200 0.540
DK150534-3800 0.300 DK150534-4300 0.560
DK150534-3900 0.400 DK150534-4400 0.580
DK150534-4000 0.500
95-3 SERIES 12-5
--- Page 17 ---
TESTING AND ADJUSTING FUEL INJECTION PUMP CALIBRATION DATA
Fuel injection Pump Assembly Number
6205-71-1350 (101495-3490)
Applicable Machine Applicable Engine
( ): Injection pump manufacturerβs part No. Model Serial No. Model Serial No.
PC78US-6 S4D95LE-3
Injection Pump Type Injection pump manufacturer
PC78UU-6
PES-A BOSCH PC78MR-6
Fuel injection pump specification Engine Specification
Rotating direction Clockwise Flywheel horsepower (kW {HP}) / rpm) 42.1 {56.5}/1,850 (Gross)
Injection order 1β2β4β3 Maximum torque (Nm {kgm} / rpm) 241 {24.6}/1,500 (Gross)
Injection interval 90Β° Β± 30β High idling speed (rpm) 2,050 Β± 50
Plunger pre-storoke (mm) 2.5 Β± 0.05 Low idling speed (rpm) 1,150 +50
+0
Delivery valve retraction volume (mm3/st) 51 Pump tester capacity for Service standard Motor 7.5 kW
Calibration Standard ( ): Fuel injection pump manufacturerβs part number
Service standard Manufacturer standard
Conditions Nozzele & nozzle holder part No. (105780-8140) 6205-11-3200 (105119-4080)
β’ Service standard Nozzele part No. (105780-0000) 6205-11-3220 (105017-3460)
indicates data
using calibration Nozzele holder part No. (105780-2080) 6205-13-3110 (105048-4450)
test parts. Injection pipe
(mm) 6 X 2 X 600 6 X 1.6 X 600
(Outside dia. x inside dia. x length)
β’ Manufacturer
standard is data Test oil ASTM D975 No.2 diesel fuel or equivalent
for factory test.
Oil temperture (Β°C) 40 β 45
2
Nozzle opening pressure (MPa{kg/cm }) 17.2 {175} 19.6 {200}
2
Transfer pump pressure (kPa{kg/cm }) 157 {1.60} 157 {1.6}
Injection volume Service standard (cc/1000 st.) Manufacturer standard (cc/1000 st.)
Rack Pump
β’ Rack positions Rack Maximum Maximum
position speed Injection Injection
B to E are the point variance variance
(mm) (rpm) volume volume
reference volume between cylinder between cylinder
when adjusting the
A
injection volume. 10.8 925 63 Β± 1 Β± 2.5 56.5
(Basic point)
B (10.8) 750 (51.5) β (59)
C approx. 7.5 575 8Β±1 Β± 15 8
Governor performance curve Boost compensator performance curve
95-3 SERIES 12-15
--- Page 18 ---
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
The basic method of using the troubleshooting chart
is as follows.
Items listed for [Questions] and [Check items] that
have a relationship with the Cause items are marked
with Q, and of these, causes that have a high proba-
bility are marked with w.
Check each of the [Questions] and [Check items]
in turn, and marked the Q or w in the chart for items
where the problem appeared. The vertical column
(Causes) that has the highest number of points is
the most probable cause, so start troubleshooting
for that item to make final confirmation of the cause.
1. For [Confirm recent repair history] in the
Causes
[Questions] Section, ask the user, and mark
the Cause column with E to use as refer-
tion)
ence for locating the cause of the failure.
injec
However, do not use this when making cal-
fuel
culations to narrow down the causes.
sive
2. Use the E in the Cause column as refer-
zzle
xce s
ence for [Degree of use (Operated for
nce
n no
p (e
long period)] in the [Questions] section
fere
g
t
jectio
men
timin
pum
inter
as reference. As a rule, do not use it when
r
nde
le
uel in
tion
ction
calculating the points for locating the
er e
ger,
, cyli
injec
cause, but it can be included if necessary to
lean
ed f
l inje
char
ring
determine the order for troubleshooting.
, seiz
fuel
air c
r fue
urbo
ton
ctive
n pis
ged
ged
rope
ed t
Defe
Clog
Clog
Seiz
Wor
Imp
Confirm recent repair history
Degree of use Operatred for long period
95-3 SERIES 12-103
--- Page 19 ---
TROUBLESHOOTING S-5
S-5 Engine does not rotate smoothly (hunting)
General causes why engine does not rotate smoothly
β’ Air in fuel system
β’ Defective governor mechanism
β’ Defective electric governor mechanism Causes
a If hunting does not occur when the rod
le
between the governor motor and the injec-
nozz
p
pum
tion pump is disconnected, troubleshoot by
tion
using the electrical system troubleshooting
feed
injec
(E mode).
l
and
e
nd fu
ap
tank
nk c
mp a
el ta
fuel
ack
d pu
or
rnor
vern
rol r
in fu
een
n fee
r
gove
aine
cont
o low
f go
betw