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Komatsu 95-2 Series User Manual

Komatsu 95-2 Series
180 pages
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1
SEBM018803
© 2002
1
All Rights Reserved
Printed in Japan 11-02(01)
00-1
3
DIESEL ENGINE
95-2 SERIES
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Komatsu 95-2 Series Specifications

General IconGeneral
BrandKomatsu
Model95-2 Series
CategoryEngine
LanguageEnglish

Summary

SAFETY

Important Safety Notice

Essential warnings for safe operation and repair procedures.

General Precautions

Guidelines for safe work practices and accident prevention.

Preparations for Work

Steps to ensure a safe working environment before starting repairs.

Precautions During Work

Safety measures to be followed while performing service tasks.

FOREWORD

Notice

Important information regarding manual updates and specifications.

How to Read the Shop Manual

Guidance on understanding manual structure, page numbering, and symbols.

Symbols

Explanation of icons used in the manual for safety and technical information.

Hoisting Instructions

Procedures and safety precautions for lifting heavy components.

Method of Disassembling, Connecting Push-Pull Type Coupler

Step-by-step guide for hydraulic coupler operations.

Coating Materials

List of recommended adhesives, sealants, and greases for assembly.

Standard Tightening Torque

Torque specifications for various nuts, bolts, and fittings.

Electric Wire Code

Table for identifying wire colors and their corresponding circuits in diagrams.

Conversion Tables

Reference charts for converting various units of measurement.

Temperature Conversion

Table for converting between Fahrenheit and Centigrade degrees.

Units

Explanation of measurement units used in the manual (SI and Gravitational).

01 GENERAL

Applicable Machine

List of machine models and engine serial numbers covered by this manual.

Specifications

Technical data and parameters for the engine model.

Weight Table

List of component weights for handling and shipping considerations.

Overall Drawing

Diagrams illustrating the engine's external dimensions and layout.

Engine Performance Curve

Graphs showing engine power, torque, and speed characteristics.

11 STRUCTURE AND FUNCTION

General Structure

Overview of the engine's main components and their arrangement.

Intake and Exhaust System

Description of the systems responsible for air intake and exhaust gas removal.

Engine Body

Detailed examination of the main engine block and its internal components.

Lubrication System

Explanation of the oil circulation system for engine lubrication.

Fuel System

Description of the components and operation of the fuel delivery system.

Cooling System

Overview of the system that regulates engine operating temperature.

Electrical System

Explanation of the starting, charging, and ignition circuits.

12 TESTING AND ADJUSTING

Adjusting Valve Clearance

Procedure for setting the correct gap for engine valves.

Measuring Compression Pressure

Method for testing cylinder compression for engine health.

Adjusting Fuel Injection Pressure

Steps to set the cracking pressure of fuel injection nozzles.

Testing and Adjusting Fuel Injection Timing

Procedure for verifying and setting engine timing.

Adjusting Fuel Cut Solenoid

Steps for adjusting the fuel cut solenoid mechanism.

Fuel Injection Pump Calibration Data

Specifications and data for testing and calibrating fuel pumps.

Performance Test

Standard values and procedures for engine performance testing.

Troubleshooting

Guide to diagnosing and resolving engine problems based on symptoms.

13 DISASSEMBLY AND ASSEMBLY

Special Tool List

List of specialized tools required for disassembly and assembly procedures.

Overall Disassembly of 4D95LE-2

Comprehensive steps for taking the engine apart.

Overall Assembly of 4D95LE-2

Comprehensive steps for reassembling the engine.

14 MAINTENANCE STANDARD

Cylinder Head

Maintenance standards and repair procedures for the cylinder head.

Valve, Valve Guide

Standards for checking and replacing valves and their guides.

Rocker Arm Shaft, Push Rod and Tappet

Maintenance standards for valve train components.

Cylinder Block

Standards for inspecting and machining the engine's main structural component.

Cylinder

Specifications and procedures for cylinder bore and liner maintenance.

Crankshaft

Standards for checking and repairing the crankshaft.

Camshaft

Specifications and procedures for the camshaft and its bearings.

Timing Gear

Maintenance standards for the engine's timing gear mechanism.

Piston, Piston Ring and Piston Pin

Standards for inspecting and replacing piston assembly parts.

Connecting Rod

Maintenance standards for connecting rods and their small end bushings.

Flywheel and Flywheel Housing

Standards for inspecting and replacing flywheel and housing.

Oil Pump

Maintenance standards for the engine's oil pump.

Regulator Valve

Standards for checking and replacing the oil pressure regulator valve.

Water Pump, Thermostat

Maintenance standards for the cooling system's water pump and thermostat.

15 REPAIR AND REPLACEMENT OF PARTS

Cylinder Head Section

Repair procedures specific to the cylinder head assembly.

Cylinder Block Section

Repair procedures specific to the cylinder block assembly.

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