Komatsu 95 Series Diesel Engines (4D95L/6D95L/3D95S/4D95S/S4D95L/S6D95L) OEM Service & Repair Manual

Shop Manual SEBE61460114 !!i SERIES DIESEL ENGINE This material is proprietary to Komatsu America International Company and is not to be reproduced, used, or disclosed except in accordance with written authorization from Komatsu America International Company. It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or add improvements at any time without incurring any obligation to install such changes on products sold previously. Due to this continuous program of research and development, periodic revisions may be made to this publication. It is recommended that customers contact their distributor for information on the latest revision. January 1998 Copyright 1998 Komatsu America International Company OO@-1

CONTENTS No. of page 01 GENERAL ......‘...............................,..........‘..,..................... 01-001 11 STRUCTURE AND FUNCTION . .... ..n................................ 11-001 12 TESTING AND ADJUSTING ,....,.,.,....................m..,.......... 12-001 13 DISASSEMBLY AND ASSEMBLY . ... .... .. .... ..... .. .. ... .... ... .. 13-001 14 MAINTENANCE STANDARD .. .. .... . .. .. ....... ... ... ...... .... .. ... .. 14-001 15 REPAIR AND REPLACEMENT .. ..... . .. ... ..... ... .... ..... ..... ... . .. 15-001 95 SERIES

LIST OF REVISED PAGES LIST OF REVISED PAGES The affected pages are indicated by the use of the following marks. It is requested that necessary actions be taken to these pages according to the table below. Mark Indication Action required 0 Page to be newly added Add 0 Page to be replaced Replace 1 1 Page to be deleted Discard Pages having no marks are those previously revised or made additions. LIST OF REVISED PAGE Mark Page Time 01 Mark Page Time of Mark Page Time 01 Vlark Page Time of Mark Page Time of revisior revision revisior revision revision 0 oo- 1 oo- 2 0 oo- 2-l 8 oo- 2-2 0 00- 2-3 0 00- 2-4 0 oo- 2-5 oo- 3 oo- 4 oo- 5 00- 6 oo- 7 oo- 8 oo- 9 00-10 00-11 00-12 00-13 00-14 00-15 00-16 00-17 00-18 00-19 0 01-001 01-002 01-003 95 SERIES 01-004 @ 0 01-005-25 @ 01-020 @ 01-041 @ 01-005 @ 0 01-005-26 @ 01-021 @ 01-041-l 0 01-005-1 @ 0 01-005-27 @ 01-021-l 0 01-041-2 @ 01-005-2 @ 0 01-005-28 @ 01-021-2 @ 01-042 @ 01-005-3 0 01-006 @ 01-022 @ 01-043 0 01-005-4 @ 01-007 0 01-023 @ 01-43-I 0 01-005-5 @ 01-008 @ 01-024 @ 01-044 @ 01-005-6 0 01-009 @ 01-025 @ 01-044-l 0 01-005-7 0 01-009-l @ 01-025-I 0 01-044-2 0 01-005-8 @ 01-009-2 @ 01-025-2 @ 01-045 0 01-005-9 @ 01-009-3 @ 01-026 @ 01-046 @ 01-005-10 @ 01-009-4 @ 01-027 @ 01-047 @ 01-005-11 @ 01-010 @ 01-028 @ 01-048 @ 01-005-12 @ 01-011 @ 01-029 @ 01-049 @ 01-005-13 @ 01-012 @ 01-030 @ 01-050 @ 01-005-14 @ 01-013 @ 01-030-1 0 01-051 @ 01-005-15 0 01-013-l @ 01-031 @ 01-052 @ 01-005-16 @ 01-013-2 @ 01-032 @ 01-053 @ (01-005-16-l) 01-013-3 @ 01-033 @ 01-054 @ (01-005-16-2) 01-013-4 @ 01-034 @ 01-055 @ 0 01-005-17 @I 01-013-5 @ 01-035 @ 01-056 0 l 01-005-18 @ 01-013-6 @ 01-036 @ 01-056-l @ 0 01-005-19 @ 01-014 @ 01-037 @ 01-057 @ 0 01-005-20 @ 01-015 @ 01-037-l @ 01-058 @ 0 01-005-21 @ 01-016 @ 01-037-2 0 01-059 0 0 01-005-22 @ 01-017 @ 01-038 @ 01-060 0 0 01-005-23 @ 01-018 @ 01-039 @ 01-060-l @ 0 01-005-24 @ 01-019 @ 01-040 @ 01-060-2 0 OOZ-'

LIST OF REWSED PAGES LIST OF REVISED PAGES Mark 01 revisior 01-060-3 0 01-061 @ 01-062 @ 01-063 @ 01-063-l @ 01-063-2 @ 01-064 @ 01-065 @ 0 01-065-I @ 01-066 @ 01-067 @ 11-001 @ 11-001-1 @ 11-001-2 @ 11-002 @ 11-003 @ 11-004 @ 11-005 @ 11-006 @ II-007 @ 11-008 @ 11-009 0 11-009-2 @ 11-010 @ 11-011 @ 11-012 @ 11-013 @ II-014 @ 11-015 @ 11-015-I @ 11-015-2 @ 11-015-3 @ 11-015-4 @ 11-015-5 @ 11-015-6 @ 11-015-7 @ 11-016 @ 11-016-l 0 11-017 @ Mark Page Time of revision 11-018 @ 11-019 @ 11-019-l @ 11-019-2 @ 11-019-3 @I 11-019-4 @ 11-019-5 @ 11-019-6 @ 11-019-7 @ 11-019-8 @ II-020 @ 11-020-1 @ 11-020-2 @ 11-020-3 @ 11-020-4 0 11-020-5 @ 11-020-6 @ 11-020-7 0 11-021 0 11-022 0 II-023 0 11-024 @ II-025 @ 11-026 @ 11-027 0 11-027-l @ 11-027-2 @ 11-028 @ 11-030 @ 11-030-1 @ 11-030-2 @ 11-031 @ 11-032 @ 11-033 @ 11-034 @ 11-035 @ 11-036 @ 11-036-l @ 11-036-2 @ II-037 @ blark Page Time of revision 11-038 @ 11-039 @ 11-040 @ II-042 @ 11-042-I @ 11-042-2 @ 11-043 @ 11-044 @ II-045 @ 11-046 @ II-047 @ 11-048 @ 11-049 @ 11-050 @ II-051 @ 11-051-l @ 11-051-2 0 11-051-3 @ 11-052 @ II-053 @ 11-054 0 II-055 @ 11-055-l @ 11-055-2 @ 11-056 @ 11-057 @ 11-058 @ 11-058-I @ 11-058-2 @ 11-058-3 @ II-059 @ II-060 @ 11-061 0 11-062 0 II-063 @ 11-063-l @ 11-063-2 @ 11-064 @ 11-065 @ 11-066 @ Clark Page Time of revision 11-067 @ 11-067-I @ 11-067-2 @ 11-067-3 @ 11-067-4 0 11-067-5 @ 11-067-6 @ 11-067-7 @ 11-067-8 @ 11-067-9 @ 11-067-10 @ 11-067-11 @ 11-067-12 @ 11-068 @ II-069 @ II-070 @ 11-071 @ 11-071-I @ 11-071-2 0 11-072 0 11-073 @ 11-073-l @ 11-073-2 @ II-074 @ 11-075 0 11-075-l @ 11-075-2 @ 11-075-3 0 11-075-4 @ 11-075-5 0 11-075-6 @ 11-075-7 0 11-075-8 @ 11-075-g @ 11-075-10 @ 11-075-11 @ 11-076 @ 11-077 @ 11-078 @ 11-079 @ dark Page Time of revision II-080 @ II-081 @ II-082 @ 11-083 @ II-084 @ 11-085 @ 11-086 @ 11-087 @ 11-087-l @ 11-087-2 @ 11-087-3 @ 11-087-4 @ 11-087-5 @ 11-087-6 @ 11-087-7 0 11-087-8 @ 11-087-g @ 11-087-10 @ 11-088 @ II-089 @ 11-090 @ 11-091 @ 11-092 @ 11-092-l 0 11-092-2 @ 11-093 @ 11-094 @ 11-095 0 11-095-l @ 11-095-2 @ 11-095-3 @ 11-095-4 @ 11-095-5 @ 11-095-6 @ 11-095-7 @ 11-095-8 @ 11-096 @ 11-096-l @ 11-096-2 @ 11-096-3 0 o”iz-2 95 SERIES

LIST OF REVISED PAGES LIST OF REVISED PAGES Mark Page Time o Mark Page Time of Mark Page Time of Mark Page Time of Clark Page Time of revisior revision revision revision revision 1 l-096-4 1 I-096-5 1 I-096-6 1I-096-8 1 l-097 1 I-098 11-098-I 11-098-Z 11-098-3 11-098-4 11-099 11-099-l 11-099-Z 11-099-3 11-100 11-101 0 12-001 12-002 12-003 12-004 12-005 12-006 12-007 12-008 12-008-I 12-009 12-010 12-010-l 12-010-2 12-010-3 12-010-4 12-010-5 12-010-6 12-010-7 12-010-8 12-010-9 95 SERIES 0 12-010-12 @ 12-022-22 @ 12-022-62 @ 12-022-102 @ 12-010-13 @ 12-022-23 @ 12-022-63 @ 12-022-103 @ 12-010-14 @ 12-022-24 @ 12-022-64 @ 12-022-104 @ 12-010-15 @ 12-022-25 @ 12-022-65 @ 12-022-105 @ 12-011 @ 12-022-26 @ 12-022-66 @ 12-022-106 @ 12-012 @ 12-022-27 @ 12-022-67 @ 12-022-107 @ 12-013 @ 12-022-28 @ 12-022-68 @ 12-022-108 @ 12-014 @ 12-022-29 @ 12-022-69 @ 12-022-109 @ 12-015 @ 12-022-30 @ 12-022-70 @ 0 12-022-110 @ 12-016 @ 12-022-31 @ 12-022-71 @ 12-023 @ 12-017 @ 12-022-32 @ 12-022-72 @ 12-024 0 12-018 @ 12-022-33 @ 12-022-73 @ 12-025 0 12-018-I 0 12-022-34 @ 12-022-74 @ 12-026 0 12-018-2 0 12-022-35 @ 12-022-75 @ 12-027 @ 12-018-3 @ 12-022-36 @ 12-022-76 @ 12-028 @ 12-019 @ 12-022-37 @ 12-022-77 @ 12-028-I 0 12-020 @ 12-022-38 @ 12-022-78 @ 0 12-028-2 @ 12-021 @ 12-022-39 @ 12-022-79 @ 12-030 @ 12-022 @ 12-022-40 @ 12-022-80 @ 12-030-I @ 12-022-I @ 12-022-41 @ 12-022-81 @ 12-030-2 0 12-022-2 @ 12-022-42 @ 12-022-82 @ 12-030-3 0 12-022-3 @ 12-022-43 @ 12-022-83 @ 12-030-4 @ 12-022-4 @ 12-022-44 @ 12-022-84 @ 12-030-5 @ 12-022-5 @ 12-022-45 @ 12-022-85 @ 12-030-6 0 12-022-6 @ 12-022-46 @ 12-022-86 @ 12-030-7 0 12-022-7 @ 12-022-47 @ 12-022-87 @ 12-030-8 0 12-022-8 @ 12-022-48 @ 12-022-88 @ 12-030-g 0 12-022-g @ 12-022-49 @ 12-022-89 @ 12-030-10 @ 12-022-10 @ 12-022-50 @ 12-022-90 @ 12-030-11 @ 12-022-11 @ 12-022-51 @ 12-022-91 @ 12-030-12 @ 12-022-12 @ 12-022-52 @ 12-022-92 @ 12-030-13 @ 12-022-13 @ 12-022-53 @ 12-022-93 @ 12-030-14 @ 12-022-14 @ 12-022-54 @ 12-022-94 @ 12-030-15 @ 12-022-15 @ 12-022-55 @ 12-022-95 @ 12-030-16 @ 12-022-16 @ 12-022-56 @ 12-022-96 @ 12-030-17 @ 12-022-17 @ 12-022-57 @ 12-022-97 @ 0 12-030-18 @ 12-022-18 @ 12-022-58 @ 12-022-98 @ 0 12-030-19 @I 12-022-19 @ 12-022-59 @ 12-022-99 @ (12-030-20) 12-022-20 @ 12-022-60 @ 12-022-100 @ 0 12-030-21 @ 12-022-21 @ 12-022-61 @ 12-022-101 @ 0 12-030-22 @ 00-2-3 aa

LIST OF REVISED PAGES LIST OF REVISED PAGES Mark Page Time of dark Page Time of Mark Page Time of Vlark Page Time of i/lark Page Time of revision revision revision revision revision 0 0 0 0 0 0 0 0 0 l 0 0 0 0 0 0 0 0 0 0 0 12-030-23 @ 12-030-24 @ 12-030-25 @ 12-030-26 @ 12-030-27 @ 12-030-28 @ 12-030-29 @ 12-030-30 @ 12-030-31 @ 12-030-32 @ 12-030-33 @ 12-030-34 @ 12-030-35 @ 12-030-36 @ 12-030-37 @ 12-030-38 @ 12-030-39 @ 12-030-40 @ 12-030-41 @ 12-030-42 @ 12-030-43 @ 12-031 12-032 12-033 12-034 12-035 12-036 12-03; 12-038 12-039 12-040 12-041 12-042 12-043 12-044 12-045 12-046 12-047 12-048 12-049 12-050 12-051 12-052 12-053 12-054 12-055 12-058 12-059 12-060 12-061 12-062 12-063 12-064 12-065 12-066 12-067 12-068 12-069 12-070 12-071 12-072 13-001 13-001-1 13-001-2 13-001-3 13-001-4 13-001-5 13-001-6 13-001-7 13-001-8 13-001-9 13-001-10 @ 13-001-11 @ 13-001-12 @ 13-001-13 @ 13-001-14 @ 13-001-15 @ 13-001-16 @ 13-001-17 @ 13-001-18 @ 13-001-19 @ 13-001-20 @ 13-001-22 @ 13-001-23 @ 13-001-24 @ 13-001-25 @ 13-001-26 @ 13-001-27 @ 13-001-28 @ 13-001-29 @ 13-001-30 @ 13-001-31 @ 13-001-32 @ 13-001-33 @ 13-001-34 @ 13-001-35 @ 13-001-36 @ 13-001-37 @ 13-001-38 @ 13-001-39 @ 13-001-40 @ 13-001-41 @ 13-001-42 @ 13-001-43 @ 13-001-44 @ 13-001-45 @ 13-001-46 @ 13-001-47 @ 13-002 13-003 13-004 13-005 13-006 13-007 13-008 13-009 13-010 13-011 13-012 13-013 @ 13-014 0 13-015 @ 13-016 @ 13-017 @ 13-018 @ 13-019 @ 13-020 0 13-021 @ 13-022 @ 13-023 @ 13-024 0 13-025 @ 13-026 @ 13-026-I @ 13-027 13-028 13-029 13-030 13-031 13-032 13-033 13-034 13-035 13-036 13-037 13-038 13-039 13-040 13-041 13-042 13-043 13-044 13-045 13-046 13-047 13-048 13-050 13-051 13-052 13-053 @ 13-054 @ 13-055 0 13-056 @ 13-057 0 13-057-I @ 13-058 0 13-059 0 13-060 @ 13-060-I @ 13-061 13-062 13-063 13-064 13-065 13-066 13-067 13-068 13-070 13-071 13-072 13-073 13-074 13-075 14-001 14-002 14-003 14-003-l 14-003-2 14-004 14-005 14-006 14-007 14-008 14-008-l 14-008-2 14-009 14-010 14-011 0°ir4 95 SERIES

LIST OF REVISED PAGES LIST OF REVISED PAGES Mark Page Time o Mark Page Time c Mark Page Time o Mark Time o revision Page revisio revision revision 14-012 14-013 14-013-l 14-013-2 14-014 14-015 14-016 14-016-I 14-016-2 14-017 14-018 14-018-I 14-018-2 14-018-3 14-01s 14-020 14-021 14-022 14-023 14-024 14-025 14-026 14-026-l 14-026-2 14-027 14-028 14-029 14-030 14-031 14-032 14-033 14-034 14-035 15-001 15-002 15-003 15-004 15-005 15-006 15-007 15-008 15-009 15-010 15-011 15-012 15-013 15-014 15-015 15-016 15-017 15-018 Mark Page Time of revision 95 SERIES 0°Z5

SAFETY SAFETY NOTICE SAFETY SAFETY NOTICE IMPORTANT SAFETY NOTICE Proper service and repair is extremely important for safe machine operation. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe. Some of these techniques require the use of tools specially designed by Komatsu for the specific purpose. To prevent injury to workers, the symbol A is used to mark safety precautions in this manual. The cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation. GENERAL PRECAUTIONS Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully BEFORE operating the machine. 1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine. 2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. . Always wear safety glasses when hitting parts with a hammer. . Always wear safety glasses when grind- ing parts with a grinder, etc. 3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, hand shield, cap and other clothes suited for welding work. When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always in- form your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator’s compartment. Keep all tools in good condition and learn the correct way to use them. 6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smok- ing. Never smoke while working. PREPARATIONS FOR WORK Before adding oil or making any repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving. Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warn- ing signs on them. 9. When disassembling or assembling, support the machine with blocks, jacks or stands before starting work. 10. Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing. 00-3

SAFETY SAFETY NOTICE PRECAUTIONS DURING WORK 11 When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. Before disconnecting or removing components of the oil, water or air circuits, first remove the pressure completely from the circuit. 12. The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned. Wait for the oil and water to cool before carrying out any work on the oil or water circuits. 13. Before starting work, remove the leads from the battery. Always remove the lead from the negative (-1 terminal first. 14. When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage. Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane. 15. When removing covers which are under in- ternal pressure or under pressure from a spring, always leave two bolts in position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove. 16. 17. 18. When removing components, be careful not to break or damage the wiring. Damaged wiring may cause electrical fires. When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips onto the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip, or can even start fires. As a general rule, do not use gasoline to wash parts. In particular, use only the mini- mum of gasoline when washing electrical parts. 21 22. 23. 24. 20. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits. Also, check that connecting parts are correctly installed. When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly. When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. When measuring hydraulic pressure, check that the measuring tool is correctly assem- bled before taking any measurements. Take care when removing or installing the tracks of track-type machines. When removing the track, the track sepa- rates suddenly, so never let anyone stand at either end of the track. 19. Be sure to assemble all parts again in their original places. Replace any damaged parts with new parts. . When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is be- ing operated. 00-4

Komatsu 95 Series Diesel Engines (4D95L/6D95L/3D95S/4D95S/S4D95L/S6D95L) OEM Service & Repair Manual

You're Reading a Preview

Recently Viewed