June 7, 2025 - Page 3 of 5

Posted on June 7, 2025 by admin

Komatsu Forklift Series 4022 (FB 20H-2R, FB 20HG-2R) & Series 4023 (FB 25H-2R, FB 30H-2R) Repair Service Manual

Complete service repair manual with Electrical Wiring Diagrams for Komatsu Forklift Series 4022 (FB 20H-2R, FB 20HG-2R) & Series 4023 (FB 25H-2R, FB 30H-2R), with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.

Komatsu Forklift Series 4022 (FB20H-2R, FB20HG-2R) & Series 4023 (FB25H-2R, FB30H-2R) workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

PRODUCT DETAILS:
Total Pages: 350 pages
File Format: PDF
Language: English

60424171 EN – Komatsu Forklift Series 4022 (FB 20H-2R, FB 20HG-2R) & Series 4023 (FB 25H-2R, FB 30H-2R) Shop Manual.pdf

MAIN SECTIONS
Chapter 00 INTRODUCTION
Chapter 10 TECHNICAL OPERATING INFORMATION
Chapter 20 CHECKS AND ADJUSTMENTS
Chapter 30 REMOVAL AND INSTALLATION OF PARTS
Chapter 40 MASTS
Chapter 50 ELECTRICAL SECTION

40248042304……1
Header……3
Table of contents……3
00 General information……9
Product information……9
Instruction and maintenance manual……9
Definition of Direction of Travel……10
General Forklift Description……10
Overall dimensions……11
Technical Data……11
Tyre characteristics……14
Forklift capacities – Model 2200 kg – Masts vertical with forks = 1400 mm max……15
Forklift capacities – Model 2500 kg short pitch – Masts vertical with forks = 1400 mm max……17
Forklift capacities – Model 2500 kg long pitch – Masts vertical with forks = 1400 mm max……19
Forklift capacities – Model 3000 kg – Masts vertical with forks = 1400 mm max……21
Alternative lift characteristics……23
Abbreviations key……24
Pneumatic tyre inflation pressure……24
Lamps……24
Battery dimensions and weights……25
Internal accessibility……26
Safety Devices……27
Transporting the Forklift……29
Forklift Towing……30
Loading and Unloading the Forklift……31
Safety precautions……32
Description of safety symbols……32
Operations Preliminary to Maintenance……32
To avoid accidents……32
General safety Regulations……33
Safety Regulations Relative to Operating Materials……36
01 Service……37
Maintenance……37
Preliminary operations before commissioning……37
Synoptic Table of Maintenance Operations……37
Supply Table……38
02 Diagnostics……39
Diagnostic software……39
Connection between the diagnostics PC and the forklift ……39
Software……40
Description of the menus in the WINPCCONSOLE software……42
Description of the PARAMETER menu ……46
Description of the TESTER menu……51
Parameters……53
Introduction……53
Parameters of the DUAL AC Master module ……54
AC3 module parameters……60
Smart Display……65
TESTER Function……69
Speed reductions……72
Alarms……73
General information on the alarms……73
Alarms of the DUAL AC module……74
Alarms of the AC3 module ……84
Alarms of the SMART DISPLAY module ……90
Analogue signals……92
Analogue signal acquisition……92
11 Drive motor……93
Asynchronous motors……93
Features of the asynchronous motors ……93
Checking the asynchronous motors ……96
Front axle motors……98
Drive motor technical data……98
Drive motor checks……101
Motor temperature sensor……104
Drive motor decomposition……106
22 Gearbox……109
Front axle……109
Front axle technical data……109
Front axle layout……111
Removal of front axle with drive motors……112
Front axle reconnection……118
Front axle disassembly……119
Front axle reassembly……120
Reducer……121
Front axle reducer layout……121
Front axle reduction gear disassembly/reassembly……122
Reduction gear oil level check……125
Reducer oil change……125
31 Vehicle……127
Bonnets……127
Bonnet layout……127
Right side bonnet removal/reassembly……128
Left side bonnet removal/reassembly……129
Battery hood removal/reassembly……129
Electronic panel bonnet removal/reassembly……133
Distributor hood removal/reassembly……133
Removal/reassembly of the operator footboard……135
Counterweight……137
Counterweight disconnection……137
Counterweight reconnection……140
34 Driver's seat……141
Fairing……141
Fairing removal/reassembly……141
Steering column panels removal/reassembly……143
Protective roof……145
Removal of the protective roof……145
Protective roof refitting……149
Lamp changes……150
42 Steering system……151
Hydraulic steering circuit……151
Power steering circuit tube connection diagram……151
Steering solenoid valve……152
Steering distributor technical data……152
Steering distributor removal……154
Steering distributor reassembly……156
Steering column……158
Steering column removal/reassembly……158
Replacement of the steering column joint……159
Steering axle……161
Steering axle technical data……161
Steering axle disconnection……162
Steering axle reconnection……165
Steering axle lubrication……166
Replacement of the steering axle bearings……167
Steering axle potentiometer……177
Replacement of the steering axle potentiometer……179
Steering cylinder……180
Steering cylinder disconnection……180
Steering cylinder reconnection……182
Replacement of the steering cylinder gaskets……183
Replacement of the cylinder connecting rod ball joints……184
46 Wheel and tyres……187
Miscellaneous……187
Safety regulations for wheels and rims……187
General information for changing tyres……188
Tyrewear check……189
Changing wheels……190
Changing the front wheel……190
Changing the rear wheel……191
Wheel disassembly……192
Disassembly/assembly of tyres on rims with movable flange……192
Quick tyres assembly/disassembly……194
Tightening torques……197
Tightening torques for single wheels……197
49 Brake system……199
Service brake……199
Brake pedal……199
Brake pedal potentiometer……199
Brake pedal removal/reassembly……200
Replacement of the brake pedal spring……201
Stop micro replacement……202
Replacement of the brake pedal potentiometer……203
Service brake adjustment……205
Parking brake……206
Microswitch features……206
Parking brake removal/reassembly……206
Parking brake wire replacement……208
Replacement of the parking brake microswitch……212
Parking brake adjustment……212
Brake group……214
Brake pad replacement……214
50 Controls……217
Accelerator pedal……217
Accelerator pedal……217
Accelerator pedal potentiometer……218
56 Display elements……221
Display……221
Multifunction panel……221
State of the display on ignition……225
State of the display during normal forklift operation……0
State of the display during an alarm situation……227
Plate data……229
Display operation ……231
60 Electrical system……233
CAN BUS……233
CAN BUS ……233
CAN BUS – Application ……236
Brake pedal potentiometer……237
Drive electrical system……239
Functions of the DUAL AC module……239
Plate data……241
DUAL AC connectors……242
Software program and parameterizations……246
Hydraulic functions electrical system……250
Functions of the AC3 module……250
Plate data……251
AC3 Connectors ……252
Software program and parameterizations……254
Electrical system components……257
Contactors……257
Fuses……258
DC/DC Converter ……259
Emergency pushbutton ……261
Buzzer……262
Fans……263
Encoder description……265
Lamps……267
Protection of the electrical system……269
71 Hydraulic equipment……271
Solenoid valve……271
Lifting hall sensor……271
Reed contacts……272
Annex……277
A Diagrams……279
Circuit diagrams……279
Electrical circuit plan – sheet 1/1……279
Hydraulic diagrams……281
Hydraulic system plan – sheet 1/1……281
Flow diagrams……283
Flow chart of functions on display……283

Komatsu Forklift Series 4022 (FB 20H-2R, FB 20HG-2R) & Series 4023 (FB 25H-2R, FB 30H-2R) Repair Service Manual

INSTANT DOWNLOAD

Posted on June 7, 2025 by admin

Komatsu Forklift Series 4016 & Series 4017 Repair Service Manual

INSTANT DOWNLOAD

Complete service repair manual with Electrical Wiring Diagrams for Komatsu Forklift Series 4016 (FB12M-2R, FB15M-2R, FB18M-2R) & Series 4017 (FB15-2R, FB18-2R), with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

Komatsu Forklift Series 4016 (FB 12, FB 15, FB 18 M-2R) & Series 4017 (FB 15, FB 18-2R) workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

PRODUCT DETAILS:
Total Pages: 345 pages
File Format: PDF
Language: English

60424131 GB – Komatsu Forklift Series 4016 (FB 12 • 15 • 18 M-2R) & Series 4017 (FB 15 • 18-2R) Shop Manual.pdf

MAIN SECTIONS
Chapter 00 Introduction
Chapter 10 Technical operating information
Chapter 20 Checks and adjustments
Chapter 30 Removal and installation of parts
Chapter 31 Masts
Chapter 40 Electrical section

Komatsu Forklift Series 4016 & Series 4017 Repair Service Manual

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Posted on June 7, 2025 by admin

Komatsu 4D98 Series, 4D106 Series, S4D106 Series Diesel Engine Repair Service Manual

INSTANT DOWNLOAD

Complete service repair manual with Electrical Wiring Diagrams for Komatsu 4D98 Series, 4D106 Series, S4D106 Series Diesel Engine, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.

Komatsu 4D98 Series, 4D106 Series, S4D106 Series Diesel Engine workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

WEBD4D9801 – 4D98 Series, 4D106 Series, S4D106 Series Diesel Engine Shop Manual.pdf

PRODUCT DETAILS:
Total Pages: 182 pages
File Format: PDF
Language: English

MAIN SECTIONS
01 GENERAL
02 TROUBLESHOOTING
03. INSPECTION AND ADJUSTMENT
04. ENGINE BODY
05. LUBRICATION SYSTEM
06. COOLING SYSTEM
07. FUEL INJECTION PUMP/GOVERNOR
08. TURBOCHARGER (FOR 4TNE106T)
09. STARTING MOTOR
10. ALTERNATOR
11. SPECICAL SERVICE TOOLS
12. SERVICE STANDARDS

MAIN MENU…..0
FOREWORD …..4
FOR SAFE SERVICING…..5
PRECAUTIONS FOR SAFE SERVICING…..6
(A) Service Shop (Place) …..6
(B) Working Wear …..7
(C) Tools to Be Used …..7
(D) Use of Genuine Parts, Oil and Grease …..7
(E) Bolt and Nut Tightening Torques …..7
(F) Electrical Parts …..8
(G) Waste Treatment …..8
(H) Handling the Product …..9
CONTENTS …..10
1. GENERAL …..11
1.1 Engine Nomenclature …..12
1.2 Specifications …..13
1.3 Fuel Oil, Lubricating Oil and Cooling Water …..17
1.4 Engine External Views…..19
1.5 Structural Description…..20
1.6 How to Read This Manual…..21
    (1) Range of Operation Explanation…..21
    (2) How to Read The Explanations…..21
    (3) Definition of Terms…..22
    (4) Abbreviations…..22
1.7 Precautions for Service Work…..23
1.8 Tightening Torques for Standard Bolts and Nuts…..24
2. TROUBLESHOOTING …..25
2.1 Quick Reference Table for Troubleshooting…..26
2.2 Troubleshooting by Measuring Compression Pressure …..29
    (1) Compression pressure measurement method…..29
    (2) Standard compression pressure…..29
    (3) Engine speed and compression pressure (reference)…..30
    (4) Measured value and troubleshooting…..30
3. INSPECTION AND ADJUSTMENT…..31
3.1 Oil Inspection …..32
3.2 Cooling Water Inspection …..32
3.3 Inspecting Water Leak from Cooling Water System and Radiator …..32
3.4 Fan Belt Tension Inspection and Adjustment …..33
3.5 Adjusting the Valve Clearance …..34
3.6 Inspecting the Fuel Injection Valve Injection Pressure and Spray Pattern …..35
3.7 Fuel Injection Timing Inspection and Adjustment…..39
3.8 Adjusting the No-load Maximum (or Minimum) Revolutions …..40
3.9 Sensor Inspection …..41
3.10 Battery Inspection …..42
3.11 Adjusting Operation …..44
3.12 Long Storage …..45
3.13 Periodic Maintenance Schedule …..46
4. ENGINE BODY …..47
4.1 Introduction …..49
4.2 Cylinder Head …..50
    (1) Components…..50
    (2) Disassembly procedure:…..50
    (3) Reassembly procedure:…..51
    (4) Servicing points…..51
    (5) Parts Inspection and measurement…..53
    (6) Valve seat correction…..56
    (7) Valve guide replacement…..58
    (8) Valve stem seal replacement…..58
4.3 Gear Train and Camshaft …..59
    (1) Components…..59
    (2) Disassembly procedure:…..59
    (3) Reassembly procedure:…..59
    (4) Servicing points…..60
    (5) Parts inspection and measurement…..62
    (6) Oil seal replacement…..64
    (7) Camshaft bushing replacement…..64
4.4 Cylinder block…..65
    (1) Components…..65
    (2) Disassembly procedure…..65
    (3) Reassembly procedure…..65
    (4) Servicing points…..66
    (5) Parts inspection and measurement…..69
    (6) Cylinder bore correction…..77
    (7) Piston pin bushing replacement…..78
    (8) Oil seal replacement…..78
5. LUBRICATION SYSTEM…..79
5.1 Lubrication System Diagram …..80
5.2 Trochoid Pump Components …..80
5.3 Disassembly (Reverse the procedure below for assembly) …..81
5.4 Servicing Points …..81
5.5 Parts Inspection and Measurement …..81
6. COOLING SYSTEM…..82
6.1 Cooling Water System …..83
6.2 Cooling Water Pump Components …..83
6.3 Disassembly (Reverse the procedure below for assembly)…..84
6.4 Servicing Points …..84
7. FUEL INJECTION PUMP/GOVERNOR…..85
7.1 Introduction …..86
7.2 Fuel Injection Pump …..86
    (1) Fuel system diagram…..86
    (2) Components…..87
    (3) Disassembly procedure:…..87
    (4) Assembly procedure…..88
    (5) Servicing points…..88
    (6) Parts inspection and measurement…..90
7.3 Fuel Injection Valve …..92
7.4 Fuel Feed Pump…..92
    (1) Components…..92
    (2) Disassembly procedure (Reverse the procedure below for assembly.)…..92
    (3) Parts inspection and measurement…..92
7.5 Governor…..93
    (1) Components…..93
    (2) Disassembly procedure (Reverse the procedure for assembly.)…..93
    (3) Parts inspection and measurement…..94
7.6 Special Service Tools for Disassembly/Assembly …..94
8. TURBOCHARGER (FOR 4TNE106T) …..95
8.1 Structure and Functions …..97
    (1) Structural and functional outline…..97
    (2) Structure…..98
    (3) Components…..99
8.2 Service Standards …..100
    (1) Service standards…..100
    (2) Tightening torque…..100
8.3 Periodic Inspection Procedure …..101
    (1) Periodic inspection intervals…..101
    (2) Inspection procedure…..101
    (3) Waste gate valve adjustment procedure…..102
8.4 Disassembly Procedure …..104
    (1) Preparation for disassembly…..104
    (2) Inspection before disassembly…..105
    (3) Disassembly…..105
8.5 Washing and Inspection procedure…..106
    (1) Washing…..106
    (2) inspection procedure…..107
8.6 Reassembly Procedure …..110
    (1) Preparation for reassembly…..110
    (2) Reassembly…..110
8.7 Handling after Disassembly and Reassembly …..112
8.8 Troubleshooting …..113
9. STARTING MOTOR …..115
9.1 FOR 4TNE94/98…..117
    9.1.1 Specifications…..117
    9.1.2 Components…..118
    9.1.3 Troubleshooting…..119
    9.1.4 Names of parts and disassembly procedure…..120
    9.1.5 Inspection and Maintenance…..124
      (1) Armature…..124
      (2) Field coil…..126
      (3) Brush…..126
      (4) Brush holder…..127
      (5) Magnetic switch…..127
      (6) Pinion clutch…..128
    9.1.6 Service standards…..130
    9.1.7 Assembly…..131
    9.1.8 Characteristic test…..133
9.2 FOR 4TNEl06(T) …..134
    9.2.1 Specifications…..134
    9.2.2 Configuration drawing…..134
    9.2.3 Troubleshooting…..135
    9.2.4 Component names and disassembly procedure…..136
    9.2.5 Disassembly procedure…..137
    9.2.6 Inspection and maintenance…..139
      (1) Armature…..139
      (2) Field coil…..141
      (3) Brush…..141
      (4) Magnetic switch continuity test…..142
      (5) Pinion…..143
      (6) Ball bearing…..143
    9.2.7 Assembly…..143
    9.2.8 Adjustment…..144
    9.2.9 Service standards…..145
10. ALTERNATOR …..146
10.1 For 4TNE94/98 …..147
    10.1.1 Specifications …..147
    10.1.2 Section view…..148
    10.1.3 Troubleshooting…..149
    10.1.4 Parts names and disassembly procedure …..150
    10.1.5 Inspection and overhaul …..153
      (1) Diode…..153
      (2) Rotor…..153
      (3) Stator…..154
      (4) Brush…..155
      (5) Check of IC regulator…..155
    10.1.6 Assembly …..157
    10.1.7 Service standards …..158
    10.1.8 Performance test …..159
10.2 For 4TNE106(T) …..160
    10.2.1 Specifications (1) …..160
    10.2.2 Exploded View …..161
    10.2.3 Troubleshooting …..162
    10.2.4 Disassembly Procedure …..163
    10.2.5 Inspection and Maintenance …..164
    10.2.6 Reassembly Procedure …..165
    10.2.7 Performance Test …..166
11. SPECIAL SERVICE TOOLS…..168
11.1 Special Tools …..169
11.2 Measuring Instruments …..171
12. SERVICE STANDARDS …..174
12.1 Engine Tuning …..175
12.2 Engine Body …..176
    (1) Cylinder head…..176
    (2) Gear train and camshaft…..177
    (3) Cylinder block…..178
12.3 Lubricating Oil System (Trochoid Pump) …..180
12.4 Tightening Torques for Main Bolts and Nuts …..181

Komatsu 4D98 Series, 4D106 Series, S4D106 Series Diesel Engine Repair Service Manuals

INSTANT DOWNLOAD

Posted on June 7, 2025 by admin

Komatsu 95E Series Diesel Engine Repair Service Manual

INSTANT DOWNLOAD

Complete service repair manual with Electrical Wiring Diagrams for Komatsu 95E Series Diesel Engines, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.

Komatsu 95E Series Diesel Engines workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

SEN01966-15 – 95E-5 Series Diesel Engine Shop Manual.pdf
SEN04357-00 – 95E-5 Series (KOHAG SPEC.) Diesel Engine Shop Manual.pdf
SEN06060-01 – 95E-6 Series Diesel Engine Shop Manual.pdf

Total Pages: 1,041 pages
File Format: PDF
Language: English

MAIN SECTIONS
01 GENERAL ……. 01-1
11 STRUCTURE AND FUNCTION …. 11-1
12 TESTING AND ADJUSTING ….. 12-1
13 DISASSEMBLY AND ASSEMBLY …. 13-1
14 MAINTENANCE STANDARD ….. 14-1
15 REPAIR AND REPLACEMENT OF PARTS … 15-1

SEN01966-15 – 95E-5 Series Diesel Engine Shop Manual……2
COVER……2
00 Index and foreword……0
Index……4
Composition of shop manual……5
Table of contents……6
Foreword and general information……12
Safety notice……13
How to read the shop manual……18
Explanation of terms for maintenance standard……20
Handling of electric equipment and hydraulic component……22
Handling of connectors newly used for engines……31
How to read electric wire code……34
Precautions when carrying out operation……37
Method of disassembling and connecting push-pull type coupler……40
Standard tightening torque table……43
Conversion table……47
01 Specification……0
Specification and technical data……54
General information……55
Specifications……57
General view……65
Weight table……74
Engine performance curves……75
10 Structure, function and maintenance standard……0
Structure, function and maintenance standard, Part 1……84
General structure……87
Air intake and exhaust unit……89
Air cleaner……91
Turbocharger……93
Muffler……96
Cylinder head……97
Cylinder block……99
Cylinder……102
Main moving parts……103
Crankshaft……105
Camshaft……106
Piston, piston ring and piston pin……107
Connecting rod……108
Flywheel and flywheel housing……111
Timing gear……113
Valve system……117
Valve, valve guide……119
Rocker arm shaft, push rod and tappet……120
Structure, function and maintenance standard, Part 2……122
Lubrication system diagram……124
Oil pump……125
Regulator valve……127
Oil filter……128
Fuel system diagram……130
Supply pump……131
Fuel injection nozzle……133
Fuel filter……134
Common rail……135
Various sensor……137
Cooling system diagram……139
Water pump……140
Cooling fan drive and thermostat……143
Starting and charging system electrical circuit diagram……147
Alternator……148
Starting motor……152
Starting aid……154
Engine controller……155
20 Standard value table……0
Standard service value table……158
Standard service value table for testing, adjusting, and troubleshooting……159
Running-in standard and performance test standard……165
30 Testing and adjusting……0
Testing and adjusting……174
Testing and adjusting tools list……176
Sketches of special tools……178
Measuring intake air pressure……179
Testing exhaust temperature……180
Adjusting valve clearance……181
Testing compression pressure……183
Testing blow-by pressure……185
Testing oil pressure……186
Handling fuel system parts……187
Releasing residual pressure in fuel system……187
Testing fuel pressure……188
Reduced cylinder mode operation……189
No-injection cranking……189
Testing leakage from pressure limiter and return rate from injector……190
Bleeding air from fuel circuit……193
Testing fuel system for leakage……195
Testing and adjusting alternator belt tension……196
Handling controller voltage circuit……197
40 Troubleshooting……0
General information on troubleshooting……200
Points on troubleshooting……201
Error code and failure code table……203
Information in troubleshooting table……205
Connection table for connector pin numbers……207
T- branch box and T- branch adapter table……243
Troubleshooting of electrical system (E-mode), Part 1……248
E-1 Code [111/CA111] ECM Critical Internal Failure……251
E-2 Code [115/CA115] Eng. Ne and Bkup Speed Sensor Error……254
E-3 Code [122/CA122] Charge Air Press Sensor High Error……255
E-4 Code [123/CA123] Charge Air Press Sensor Low Error……257
E-5 Code [131/CA131] Throttle Sensor High Error……258
E-6 Code [132/CA132] Throttle Sensor Low Error……261
E-7 Code [144/CA144] Coolant Temp. Sensor High Error……263
E-8 Code [145/CA145] Coolant Temp. Sensor Low Error……265
E-9 Code [153/CA153] Charge Air Temp. Sensor High Error……267
E-10 Code [154/CA154] Charge Air Temp. Sensor Low Error……269
E-11 Code [187/CA187] Sensor Sup. 2 Volt. Low Error……270
E-12 Code [221/CA221] Ambient Air Press. Sensor High Error……271
E-13 Code [222/CA222] Ambient Air Press. Sensor Low Error……273
E-14 Code [227/CA227] Sensor Sup. 2 Volt. High Error……274
E-15 Code [234/CA234] Eng. Overspeed……275
E-16 Code [238/CA238] Ne Speed Sensor Sup. Volt. Error……277
E-17 Code [271/CA271] IMV Short Error……279
E-18 Code [272/CA272] IMV Open Error……281
E-19 Code [322/CA322] Injector #1 System Open/Short Error……283
E-20 Code [324/CA324] Injector #3 System Open/Short Error……285
E-21 Code [331/CA331] Injector #2 System Open/Short Error……287
E-22 Code [332/CA332] Injector #4 System Open/Short Error……289
E-23 Code [351/CA351] INJ. Drive Circuit Error……291
E-24 Code [352/CA352] Sensor Sup. 1 Volt. Low Error……294
E-25 Code [386/CA386] Sensor Sup. 1 Volt. High Error……295
E-26 Code [431/CA431] Idle Validation SW Low error……297
E-27 Code [432/CA432] Idle Validation Process error……297
E-28 Code [435/CA435] Abnormality in engine oil pressure switch……298
E-29 Code [441/CA441] Battery voltage low error……299
E-30 Code [442/CA442] Battery voltage high error……299
Troubleshooting of electrical system (E-mode), Part 2……302
E-31 Code [449/CA449] Rail Press. Very High Error……304
E-32 Code [451/CA451] Rail Press. Sensor High Error……305
E-33 Code [452/CA452] Rail Press. Sensor Low Error……307
E-34 Code [553/CA553] Rail Press. High Error……308
E-35 Code [559/CA559] Rail Press. Low Error……309
E-36 Code [689/CA689] Eng. Ne Speed Sensor Error……313
E-37 Code [731/CA731] Eng. Bkup Speed Sensor Phase Error……315
E-38 Code [757/CA757] All Persistent Data Lost Error……316
E-39 Code [778/CA778] Eng. Bkup Speed Sensor Error……317
E-40 Code [1633/CA1633] KOMNET Dtalink Timeout Error……319
E-41 Code [2185/CA2185] Throttle Sens. Sup. Volt. High Error……320
E-42 Code [2186/CA2186] Throttle Sens. Sup. Volt. Low Error……323
E-43 Code [2249/CA2249] Rail Press. Very Low Error……324
E-44 Code [2311/CA2311] Abnormality in IMV solenoid……325
E-45 Code [2555/CA2555] Grid Heater Relay Volt. Low Error……326
E-46 Code [2556/CA2556] Grid Heater Relay Volt. High Error……327
E-47 Code [(—)/B@BAZG] Eng. Oil press. Low Speed Derate……329
E-48 Code [(—)/B@BAZG] Eng. Oil press. Torque Derate……329
E-49 Code [(—)/B@BCNS] Eng. Overheat……330
Troubleshooting of mechanical system (S-mode)……332
Method of using troubleshooting charts……335
S-1 Starting performance is poor……339
S-2 Engine does not start……340
S-3 Engine does not pick up smoothly……343
S-4 Engine stops during operations……344
S-5 Engine does not rotate smoothly……345
S-6 Engine lacks output (or lacks power)……346
S-7 Exhaust smoke is black (incomplete combustion)……347
S-8 Oil consumption is excessive (or exhaust smoke is blue)……348
S-9 Oil becomes contaminated quickly……349
S-10 Fuel consumption is excessive……350
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)……351
S-12 Oil pressure drops……352
S-13 Oil level rises (Entry of coolant or fuel)……353
S-14 Coolant temperature becomes too high (overheating)……354
S-15 Abnormal noise is made……355
S-16 Vibration is excessive……356
50 Disassembly and assembly……0
General information on disassembly and assembly……358
How to read this manual……359
Coating materials list……361
Special tools list……364
Sketches of special tools……365
Disassembly and assembly, Part 1……368
General disassembly of engine……369
Disassembly and assembly, Part 2……382
General assembly of engine……383
Disassembly and assembly, Part 3……400
Disassembly and assembly procedure for fuel supply pump unit……401
Disassembly and assembly procedure for oil seal units……403
90 Repair and replacement of parts……0
Information related to repair and replacement……406
Special tool table……407
Sketches of special tools……409
Parts related to cylinder head……412
Part names related to cylinder head……413
Testing and inspection of cylinder head……414
Pressure test of cylinder head……416
Replacement of valve guide……416
Replacement of valve seat insert……418
Repair of cylinder head mounting face by grinding……424
Repair of valve by grinding……425
Parts related to cylinder block……428
Part names related to cylinder block……429
Testing and inspection of cylinder block……430
Part names related to crankshaft……433
Testing and inspection of crankshaft……434
Part names related to connecting rod……435
Testing and inspection of connecting rod……436
Replacement of flywheel ring gear……437
Replacement of crankshaft gear……438
Replacement of camshaft gear……438
Replacement of connecting rod small end bushing……439
Replacement of cam bushing……441
Cylinder liner (Special part for repair)……443
Rework drawing for counter bore……444
Repair of crankshaft by grinding……445
SEN04357-00 – 95E-5 Series (KOHAG SPEC.) Diesel Engine Shop Manual……450
SEN04357-00 WA90-6, WA100M-6……450
00 Index and foreword……452
Index……452
Composition of shop manual……453
Table of contents……454
Foreword and general information……460
Safety notice……461
How to read the shop manual……466
Explanation of terms for maintenance standard……468
Handling of electric equipment and hydraulic component……470
Handling of connectors newly used for engines……479
How to read electric wire code……482
Precautions when carrying out operation……485
Method of disassembling and connecting push-pull type coupler……488
Standard tightening torque table……491
Conversion table……495
01 Specification……502
Specification and technical data……502
Outline……503
Specifications……505
General view……507
Weight table……510
Engine performance curves……511
10 Structure, function and maintenance standard……516
Structure, function and maintenance standard, Part 1……516
General structure……519
Air intake and exhaust system……521
Air intake and exhaust unit……521
Turbocharger……523
Engine unit……527
Cylinder head……527
Cylinder block……529
Cylinder……532
Main moving parts……533
Crankshaft……535
Camshaft……536
Piston, piston ring and piston pin……537
Connecting rod……538
Flywheel and flywheel housing……539
Timing gear……541
Valve system……545
Valve, valve guide……547
Rocker arm shaft, push rod and tappet……548
Structure, function and maintenance standard, Part 2……550
Lubrication system……552
Lubrication system diagram……552
Oil pump……553
Regulator valve……555
Oil filter……556
Fuel system……558
Fuel system diagram……558
Supply pump……559
Fuel injection nozzle……561
Fuel filter……562
Common rail……563
Various sensor……565
Cooling system……567
Cooling system diagram……567
Water pump……568
Cooling fan drive and thermostat……571
Electrical equipment……575
Starting and charging system electrical circuit diagram……575
Alternator……576
Starting motor……578
Starting aid……579
Engine controller……580
20 Standard value table……582
Standard service value table……582
Standard service value table for testing, adjusting, and troubleshooting……583
Running-in standard and performance test standard……584
30 Testing and adjusting……588
Testing and adjusting……588
Testing and adjusting tools list……590
Measuring intake air pressure……591
Testing exhaust temperature……592
Adjusting valve clearance……593
Testing compression pressure……595
Testing blow-by pressure……597
Testing oil pressure……598
Handling fuel system parts……599
Releasing residual pressure in fuel system……599
Testing fuel pressure……600
Reduced cylinder mode operation……601
No-injection cranking……601
Testing leakage from pressure limiter and return rate from injector……602
Bleeding air from fuel circuit……605
Testing fuel system for leakage……607
Testing and adjusting alternator belt tension……608
Handling controller voltage circuit……609
40 Troubleshooting……612
General information on troubleshooting……612
Points on troubleshooting……613
Error code and failure code table……615
Information in troubleshooting table……617
Troubleshooting of electrical system (E-mode), Part 1……620
E-1 Code [111/CA111] ECM Critical Internal Failure……623
E-2 Code [115/CA115] Eng. Ne and Bkup Speed Sensor Error……626
E-3 Code [122/CA122] Charge Air Press Sensor High Error……627
E-4 Code [123/CA123] Charge Air Press Sensor Low Error……629
E-5 Code [131/CA131] Throttle Sensor High Error……630
E-6 Code [132/CA132] Throttle Sensor Low Error……633
E-7 Code [144/CA144] Coolant Temp. Sensor High Error……634
E-8 Code [145/CA145] Coolant Temp. Sensor Low Error……635
E-9 Code [153/CA153] Charge Air Temp. Sensor High Error……637
E-10 Code [154/CA154] Charge Air Temp. Sensor Low Error……639
E-11 Code [187/CA187] Sensor Sup. 2 Volt. Low Error……640
E-12 Code [221/CA221] Ambient Air Press. Sensor High Error……641
E-13 Code [222/CA222] Ambient Air Press. Sensor Low Error……643
E-14 Code [227/CA227] Sensor Sup. 2 Volt. High Error……644
E-15 Code [234/CA234] Eng. Overspeed……646
E-16 Code [238/CA238] Ne Speed Sensor Sup. Volt. Error……647
E-17 Code [271/CA271] IMV Short Error……649
E-18 Code [272/CA272] IMV Open Error……651
E-19 Code [322/CA322] Injector #1 (L/B #1) System Open/Short Error……653
E-20 Code [324/CA324] Injector #3 (L/B #3) System Open/Short Error……655
E-21 Code [331/CA331] Injector #2 (L/B #2) System Open/Short Error……657
E-22 Code [332/CA332] Injector #4 (L/B #4) System Open/Short Error……659
E-23 Code [351/CA351] INJ. Drive Circuit Error……661
E-24 Code [352/CA352] Sensor Sup. 1 Volt. Low Error……664
E-25 Code [386/CA386] Sensor Sup. 1 Volt. High Error……665
E-26 Code [431/CA431] Idle Validation SW Low error……667
E-27 Code [432/CA432] Idle Validation Process error……667
E-28 Code [435/CA435] Abnormality in engine oil pressure switch……668
E-29 Code [441/CA441] Battery voltage low error……669
E-30 Code [442/CA442] Battery voltage high error……669
Troubleshooting of electrical system (E-mode), Part 2……672
E-31 Code [449/CA449] Rail Press. Very High Error……674
E-32 Code [451/CA451] Rail Press. Sensor High Error……675
E-33 Code [452/CA452] Rail Press. Sensor Low Error……677
E-34 Code [553/CA553] Rail Press. High Error……678
E-35 Code [559/CA559] Rail Press. Low Error……679
E-36 Code [689/CA689] Eng. Ne Speed Sensor Error……683
E-37 Code [731/CA731] Eng. Bkup Speed Sensor Phase Error……685
E-38 Code [757/CA757] All Persistent Data Lost Error……686
E-39 Code [778/CA778] Eng. Bkup Speed Sensor Error……687
E-40 Code [1633/CA1633] KOMNET Dtalink Timeout Error……689
E-41 Code [2185/CA2185] Throttle Sens. Sup. Volt. High Error……690
E-42 Code [2186/CA2186] Throttle Sens. Sup. Volt. Low Error……693
E-43 Code [2249/CA2249] Rail Press. Very Low Error……694
E-44 Code [2311/CA2311] Abnormality in IMV solenoid……695
E-45 Code [2555/CA2555] Grid Heater Relay Volt. Low Error……697
E-46 Code [2556/CA2556] Grid Heater Relay Volt. High Error……699
E-47 Code [(- – -)/B@BAZG] Eng. Oil press. Low Speed Derate……701
E-48 Code [(- – -)/B@BAZG] Eng. Oil press. Torque Derate……701
E-49 Code [(- – -)/B@BCNS] Eng. Overheat……702
Troubleshooting of mechanical system (S-mode)……704
Method of using troubleshooting charts……707
S-1 Starting performance is poor……711
S-2 Engine does not start……712
S-3 Engine does not pick up smoothly……715
S-4 Engine stops during operations……716
S-5 Engine does not rotate smoothly……717
S-6 Engine lacks output (or lacks power)……718
S-7 Exhaust smoke is black (incomplete combustion)……719
S-8 Oil consumption is excessive (or exhaust smoke is blue)……720
S-9 Oil becomes contaminated quickly……721
S-10 Fuel consumption is excessive……722
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)……723
S-12 Oil pressure drops……724
S-13 Oil level rises (Entry of coolant or fuel)……725
S-14 Coolant temperature becomes too high (overheating)……726
S-15 Abnormal noise is made……727
S-16 Vibration is excessive……728
50 Disassembly and assembly……730
General information on disassembly and assembly……730
How to read this manual……731
Coating materials list……732
Special tools list……735
Disassembly and assembly, Part 1……738
General disassembly of engine……739
Disassembly and assembly, Part 2……752
General assembly of engine……753
Disassembly and assembly, Part 3……770
Disassembly and assembly procedure for fuel supply pump unit……771
Disassembly and assembly procedure for oil seal units……773
SEN06060-01 – 95E-6 Series Diesel Engine Shop Manual……776
COVER……776
00 Index and foreword ……778
Index ……779
Foreword, safety and general information ……782
Important safety notice ……782
How to read the shop manual ……789
Explanation of terms for maintenance standard ……791
Handling equipment of fuel system devices ……793
Handling of intake system parts ……794
Handling of hydraulic equipment ……795
Method of disconnecting and connecting of push-pull type coupler ……797
Handling of electrical equipment ……800
How to read electric wire code ……808
Precautions when performing operation ……811
Standard tightening torque table ……816
List of abbreviation ……822
Conversion table ……827
01 Specification ……832
Table of contents ……833
General information ……834
Exhaust gas regulation ……834
Specifications ……837
Applicable machines ……837
Specifications ……838
General view ……841
Weight table ……850
Engine performance curve ……851
10 Structure and function ……854
Table of contents ……855
Components layout ……856
Components layout drawing ……856
Intake and exhaust system parts ……858
Intake and exhaust system layout drawing ……858
Intake and exhaust system circuit diagram ……860
Air cleaner ……862
VFT ……863
EGR system piping drawing ……867
EGR system circuit diagram ……869
EGR valve ……870
EGR cooler ……872
KCCV layout drawing ……874
KCCV ventilator ……876
KDOC muffler ……880
Engine main body parts ……882
General structure ……882
Cylinder head ……886
Cylinder block ……888
Main moving parts ……890
Timing gear ……893
Front cover ……895
Valve system ……896
Flywheel and flywheel housing ……898
Lubrication system ……899
Lubrication system chart ……899
Oil pump ……901
Oil filter ……903
Oil cooler ……905
Oil pan ……906
Fuel system ……907
Fuel system parts layout drawing ……907
Fuel system circuit diagram ……909
Prefilter ……910
Main filter ……911
Supply pump ……912
Common rail ……913
Injector ……914
Cooling system ……918
Cooling system parts layout drawing ……918
Cooling system chart ……919
Drive pulley ……920
Water pump ……922
Thermostat and jiggle valve ……923
Electrical equipment ……927
Alternator ……927
Starting motor ……932
Intake air heater ……936
Engine harness ……937
Engine controller ……939
Sensor ……945
20 Standard value tables ……954
Table of contents ……955
Standard service value table ……956
Standard value table for engine ……956
Running-in standard and performance test standard ……960
50 Disassembly and assembly ……964
Table of contents ……965
Related information on disassembly and assembly ……966
How to read this manual ……966
Coating materials list ……968
Special tools list ……972
Sketches of special tools ……973
Disassembly and assembly ……974
General disassembly of engine ……974
General assembly of engine ……989
Removal and installation procedure of supply pump unit alone ……1012
Engine front oil seal replacement procedure ……1015
Engine rear oil seal replacement procedure ……1016
60 Maintenance standard ……1018
Table of contents ……1019
Intake and exhaust system parts ……1020
VFT ……1020
Engine main body parts ……1021
Cylinder head ……1021
Cylinder block ……1023
Crankshaft ……1025
Piston ……1026
Connecting rod ……1027
Timing gear ……1028
Camshaft ……1029
Valve system ……1030
Valve and valve guide ……1031
Rocker arm shaft, push rod, and tappet ……1032
Flywheel and flywheel housing ……1033
Lubrication system ……1035
Oil pump ……1035
Cooling system ……1037
Water pump ……1037
INDEX……1038

Komatsu 95E Series Diesel Engine Repair Service Manuals

INSTANT DOWNLOAD

Posted on June 7, 2025 by admin

Komatsu 95 Series Diesel Engine Repair Service Manuals

INSTANT DOWNLOAD

Complete service repair manual with Electrical Wiring Diagrams for Komatsu 95 Series Diesel Engines, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

Komatsu 95 Series Diesel Engines workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

SEBE61460114 – 95 Series Diesel Engine Shop Manual.pdf
SEBM018803 – 95-2 Series Diesel Engine Shop Manual.pdf
SEBM031001 – 95-3 Series Diesel Engines Shop Manual.pdf
SEN04408-00 – 95 Series Diesel Engine Shop Manual.pdf

PRODUCT DETAILS:
Total Pages: 1,422 pages
File Format: PDF
Language: English

SEBE61460114 – 95 Series Diesel Engine Shop Manual…………….2
CONTENTS…………….3
01 GENERAL …………….28
GENERAL VIEW …………….29
SPECIFICATIONS …………….31
GENERAL ASSEMBLY DRAWING …………….53
ENGINE PERFORMANCE CURVE …………….95
WEIGHT TABLE…………….155
11 STRUCTURE AND FUNCTION …………….158
GENERAL STRUCTURE …………….159
INTAKE AND EXHAUST SYSTEM …………….170
INTAKE AND EXHAUST SYSTEM…………….170
FTG AIR CLEANER…………….186
TURBOCHARGER…………….190
AFTER-COOLER…………….197
ENGINE BODY…………….199
CYLINDER HEAD…………….199
VALVE SYSTEM…………….219
CYLINDER BLOCK…………….227
CYLINDER LINER…………….233
MAIN CIRCULATION SYSTEM…………….235
TIMING GEAR…………….253
FLYWHEEL AND FLYWHEEL HOUSING…………….259
LUBRICATION SYSTEM…………….264
LUBRICATION SYSTEM CHART…………….264
OIL PUMP …………….270
OIL FILTER …………….271
OIL COOLER …………….273
FUEL SYSTEM …………….275
FUEL SYSTEM CHART …………….275
FUEL INJECTION PUMP …………….287
GOVERNOR…………….317
FEED PUMP…………….321
FUEL INJECTION NOZZLE …………….323
FUEL CUT SOLENOID …………….326
ENGINE STOP MOTOR …………….329
FUEL FILTER …………….334
WATER SEPARATOR …………….335
COOLING SYSTEM …………….336
COOLING SYSTEM CHART …………….336
WATER PUMP …………….339
CORROSION RESISTOR (OPTION) …………….342
THERMOSTAT AND FAN DRIVE …………….343
ELECTRICAL SYSTEM…………….353
ALTERNATOR…………….353
STARTING MOTOR …………….362
ELECTRICAL INTAKE AIR HEATER …………….368
ACCESSORY…………….373
AIR COMPRESSOR…………….373
12 TESTING AND ADJUSTING…………….376
INTAKE AND EXHAUST SYSTEM…………….377
ADJUSTING VALVE CLEARANCE…………….377
MEASURING EXHAUST GAS COLOR…………….379
ENGINE BODY…………….380
MEASURING COMPRESSION PRESSURE…………….380
MEASURING BLOW-BY PRESSURE…………….381
ADJUSTING ENGINE SPEED SENSOR…………….382
FUEL SYSTEM…………….383
CHECKING AND ADJUSTING FUEL INJECTION TIMING…………….383
ADJUSTING GOVERNOR…………….393
TESTING AND ADJUSTING FUEL CUT SOLENOID…………….396
PROCEDURE FOR ADJUSTING ENGINE STOP MOTOR CABLE…………….401
ADJUSTING FUEL INJECTION PRESSURE…………….403
LUBRICATION SYSTEM…………….406
MEASURING OIL PRESSURE…………….406
MEASURING OIL TEMPERATURE…………….407
COOLING SYSTEM…………….408
MEASURING WATER TEMPERATURE…………….408
TESTING AND ADJUSTING FAN BELT TENSION…………….409
FUEL INJECTION PUMP CALIBRATION DATA…………….410
PERFORMANCE TEST…………….529
RUN-IN STANDARD…………….529
PERFORMANCE TEST CRITERIA…………….538
TESTING AND ADJUSTING TOOL LIST…………….559
TESTING AND ADJUSTING DATA…………….560
TROUBLESHOOTING…………….583
METHOD OF USING TROUBLESHOOTING TABLE…………….584
POINTS TO REMEMBER WHEN TROUBLESHOOTING…………….588
S-1 Starting performance is poor (Starting always takes time) …………….589
S-2 Engine does not start…………….590
(1) Engine does not turn…………….590
(2) Engine turns but no exhaust gas comes out (Fuel is not being injected)…………….591
(3) Exhaust gas comes out but engine does not start (Fuel is being injected)…………….592
S-3 Engine does not pick up smoothly (Follow-up is poor) …………….593
S-4 Engine stops during operations …………….594
S-5 Engine does not rotate smoothly …………….595
S-6 Engine lacks output (no power) …………….596
S-7 Exhaust gas is black (incomplete combustion) …………….597
S-8 Oil consumption is excessive (or exhaust gas is blue)…………….598
S-9 Oil becomes contaminated quickly …………….599
S-10 Fuel consumption is excessive …………….600
S-11 Oil is in cooling water, or water spurts back, or water level …………….601
S-12 Oil pressure lamp lights up (drop in oil pressure) …………….602
S-13 Oil level rises…………….603
S-14 Water temperature becomes too high (overheating) …………….604
S-15 Abnormal noise is made…………….605
S-16 Vibration is excessive…………….606
S-17 Diagnosis of electronical governor by diagnosis display (electronical governor made by ZEXEL)…………….607
13 DISASSEMBLY AND ASSEMBLY…………….623
3D95S-W-1…………….624
GENERAL DISASSEMBLY…………….625
GENERAL ASSEMBLY …………….632
4D95S-1…………….645
GENERAL DISASSEMBLY…………….646
GENERAL ASSEMBLY …………….656
4D95L SERIES…………….672
GENERAL DISASSEMBLY…………….672
GENERAL ASSEMBLY…………….686
6D95L SERIES…………….708
GENERAL DISASSEMBLY…………….708
GENERAL ASSEMBLY…………….722
DISASSEMBLY AND ASSEMBLY OF AIR COMPRESSOR…………….746
14 MAINTENANCE STANDARD …………….753
TURBOCHARGER …………….754
CYLINDER HEAD …………….757
VALVE, VALVE GUIDE…………….762
ROCKER ARM SHAFT, PUSH ROD AND TAPPET…………….765
CYLINDER BLOCK …………….766
CRANKSHAFT …………….768
CAMSHAFT …………….772
TIMING GEAR (HELICAL GEAR) …………….778
FLYWHEEL AND FLYWHEEL HOUSING …………….783
PISTON, PISTON RING AND PISTON PIN…………….784
CONNECTING ROD …………….793
OIL PUMP …………….794
REGULATOR VALVE …………….796
WATER PUMP, THERMOSTAT …………….797
FUEL SYSTEM …………….800
15 REPAIR AND REPLACEMENT …………….803
CYLINDER HEAD SECTION…………….805
GRINDING CYLINDER HEAD MOUNTING SURFACE …………….805
REPLACING VALVE SEAT INSERT…………….806
REPLACING VALVE GUIDE …………….810
GRINDING VALVE …………….811
CYLINDER BLOCK SECTION…………….812
REPLACING CAM BUSHING …………….812
REPLACING GEARS…………….814
PROCEDURE FOR PRESSURE TEST …………….816
CYLINDER LINER (SPECIAL RESTORATION PART) …………….817
MACHINING DRAWING FOR CYLINDER BLOCK BORE …………….818
ADDITIONAL MACHINING OF CAM JOURNAL …………….819
GRINDING CRANKSHAFT …………….820
SEBM018803 – 95-2 Series Diesel Engine Shop Manual…………….822
COVER…………….822
CONTENTS…………….823
SAFETY…………….826
SAFETY NOTICE…………….826
FOREWORD…………….828
GENERAL…………….828
HOW TO READ THE SHOP MANUAL…………….829
HOISTING INSTRUCTIONS…………….830
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER…………….831
COATING MATERIALS…………….833
STANDARD TIGHTENING TORQUE…………….835
ELECTRIC WIRE CODE…………….838
CONVERSION TABLE…………….839
UNITS…………….845
01 GENERAL…………….846
APPLICABLE MACHINE…………….847
SPECIFICATIONS…………….848
WEIGHT TABLE…………….850
OVERALL DRAWING …………….851
ENGINE PERFORMANCE CURVE…………….854
11 STRUCTURE AND FUNCTION…………….857
GENERAL STRUCTURE…………….858
GENERAL STRUCTURE…………….858
INTAKE AND EXHAUST SYSTEM …………….860
INTAKE AND EXHAUST SYSTEM …………….860
AIR CLEANER…………….862
ENGINE BODY…………….864
CYLINDER HEAD…………….864
CYLINDER BLOCK…………….866
MAIN CIRCULATION SYSTEM…………….868
TIMING GEAR…………….870
VALVE SYSTEM …………….872
FLYWHEEL AND FLYWHEEL HOUSING…………….874
LUBRICATION SYSTEM …………….876
LUBRICATION SYSTEM CHART…………….876
OIL PUMP…………….877
OIL FILTER …………….878
OIL FILTER MOUNT…………….879
FUEL SYSTEM …………….881
FUEL SYSTEM CHART…………….881
FUEL INJECTION PUMP…………….882
FUEL INJECTION NOZZLE…………….884
FUEL FILTER…………….885
ENGINE CUT SOLENOID…………….886
COOLING SYSTEM…………….887
COOLING SYSTEM CHART…………….887
WATER PUMP…………….888
FAN DRIVE AND THERMOSTAT…………….889
ELECTRICAL SYSTEM …………….892
STARTING AND CHARGING SYSTEM ELECTRICAL CIRCUIT DIAGRAM…………….892
ALTERNATOR…………….893
STARTING MOTOR…………….894
ENGINE STARTING DEVICE…………….895
12 TESTING AND ADJUSTING…………….896
TESTING AND ADJUSTING…………….897
ADJUSTING VALVLE CLEARANCE…………….897
MEASURING COMPRESSION PRESSURE…………….899
ADJUSTING FUEL INJECTION PRESSURE…………….900
TESTING AND ADJUSTING FUEL INJECTION TIMING…………….901
ADJUSTING FUEL CUT SOLENOID…………….905
FUEL INJECTION PUMP CALIBRATION DATA…………….908
PERFORMANCE TEST …………….911
RUN-IN STANDARD…………….911
PERFORMANCE TEST CRITERIA …………….912
TROUBLESHOOTING…………….914
METHOD OF USING TROUBLESHOOTING CHARTS…………….915
POINTS TO REMEMBER WHEN TROUBLESHOOTING…………….919
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)…………….920
S-2 ENGINE DOES NOT START…………….921
(1) ENGINE DOES NOT TURN…………….921
(2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED)…………….922
(3) EXHAUST SMOKE COMES OUT, BUT ENGINE DOES NOT START (FUEL IS NOT BEING INJECTED)…………….923
S-3 ENGINE DOES NOT PICK UP SMOOTHLY…………….924
S-4 ENGINE STOPS DURING OPERATIONS…………….925
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)…………….926
S-6 ENGINE LACK OUTPUT (NO POWER)…………….927
S-7 EXHAUST GAS IS BLACK…………….928
S-8 OIL CONSUMPTION IS EXCESSIVE, OR EXHAUST GAS IS BLUE…………….929
S-9 OIL BECOMES CONTAMINATED QUICKLY…………….930
S-10 FUEL CONSUMPTION IS EXCESSIVE…………….931
S-11 OIL IS IN COOLING WATER …………….932
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UPS (DROP IN OIL PRESSURE)…………….933
S-13 OIL LEVEL RISES (WATER, FUEL IN OIL )…………….934
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)…………….935
S-15 ABNORMAL NOISE IS MADE…………….936
S-16 VIBRATION IS EXCESSIVE…………….937
TESTING AND ADJUSTING TOOL LIST…………….938
TESTING AND ADJUSTING DATA…………….939
13 DISASSEMBLY AND ASSEMBLY…………….941
SPECIAL TOOL LIST…………….942
OVERALL DISASSEMBLY OF 4D95LC-2…………….943
PREPARATORY WORK…………….944
1. ALTERNATOR, FAN PULLEY…………….944
2. STARTING MOTOR, ENGINE STOP SOLENOID, FUEL AND OIL FILTERS, DIPSTICK…………….945
3. WATER PUMP…………….945
4. FUEL INJECTION TUBE, GLOW PLUG…………….945
5. INJECTION NOZZLE…………….945
6. FUEL INJECTION PUMP…………….946
7. INTAKE MANIFOLD…………….946
8. EXHAUST MANIFOLD…………….946
9. HEAD COVER…………….946
10. ROCKER ARM…………….947
11. PUSH ROD, CYLINDER HEAD MOUNTING BOLT…………….947
12. CYLINDER HEAD COVER…………….947
13. PTO SHAFT…………….948
14. OIL PAN…………….949
15. OIL SUCTION PIPE…………….949
16. CRANKSHAFT PULLEY…………….949
17. GEAR CASE COVER…………….949
18. OIL PUMP, IDLER GEAR…………….950
19. CAMSHAFT ASSEMBLY…………….950
20. FLYWHEEL…………….950
21. FLYWHEEL HOUSING…………….951
22. PISTION, CONNECTING ROD ASSEMBLY…………….951
23. MAIN CAP…………….953
24. CRANKSHAFT…………….954
25. TAPPET…………….954
26.CYLINDER BLOCK ASSEMBLY…………….954
OVERALL ASSEMBLY…………….955
1. CYLINDER BLOCK ASSEMBLY…………….955
2. TAPPET…………….955
3. CRANKSHAFT…………….955
4. MAIN CAP…………….956
5. FLYWHEEL HOUSING…………….959
6. FLYWHEEL…………….960
7. CAMSHAFT ASSEMBLY…………….960
8. OIL PUMP, IDLER GEAR…………….961
9. GEAR CASE COVER…………….962
10. CRANKSHAFT PULLEY…………….962
11. OIL SUCTION PIPE…………….962
12. OIL PAN…………….963
13. PTO SHAFT…………….963
14. FUEL INJECTION PUMP…………….963
15. CYLINDER HEAD ASSEMBLY…………….964
16. ADJUSTMENT OF VALVE CLEARANCE…………….966
17. HEAD COVER…………….967
18. EXHAUST MANIFOLD…………….967
19. INTAKE MANIFOLD…………….967
20. INJECTION NOZZLE…………….967
21. FUEL INJECTION TUBE, GLOW PLUG…………….968
22. WATER PUMP…………….968
23. STARTING MOTOR. ENGINE STOP SOLENOID, FUEL AND OIL FILTERS, DIPSTICK…………….968
24. ALTERNATOR, FAN PULLEY…………….969
25. ENGINE ASSEMBLY…………….969
26. FAN, EXHAUST PIPE, MUFFLER, ENGINE OIL TUBES, BLOCK, COVER…………….970
14 MAINTENANCE STANDARD…………….971
CYLINDER HEAD…………….972
VALVE AND VALVE GUIDE…………….973
ROCKER ARM SHAFT, PUSH ROD AND TAPPET…………….974
CYLINDER BLOCK…………….975
CYLINDER…………….976
CRANKSHAFT…………….977
CAMSHAFT…………….978
TIMING GEAR…………….979
PISTION, PISTON RING AND PISTION PIN…………….980
CONNECTING ROD…………….981
FLYWHEEL AND FLYWHEEL HOUSING…………….982
OIL PUMP…………….983
REGULATOR VALVE…………….984
WATER PUMP AND THERMOSTAT…………….985
15 REPAIR AND REPLACEMENT OF PARTS…………….986
CYLINDER HEAD SECTION…………….987
GRINDING CYLINDER HEAD MOUNTING SURFACE…………….987
REPLACING VALVE GUIDE…………….988
GRINDING VALVE…………….989
CYLINDER BLOCK SECTION…………….990
REPLACING CAMSHAFT BUSHING…………….990
REPLACING CRANKSHAFT GEAR…………….992
REPLACING CAM GEAR…………….993
REPLACING FLYWHEEL RING GEAR…………….994
PROCEDURE FOR PRESSURE TEST …………….995
CYLINDER LINER (SPECIAL RESTORATION PART)…………….996
MACHINING DRAWING FOR CYLINDER BLOCK BORE…………….997
ADDITIONAL MACHINING OF CAM JOURNAL…………….998
GRINDING CRANKSHAFT…………….999
REPLACING CONNECTING ROD SMALL END BUSHING…………….1000
SEBM031001 – 95-3 Series Diesel Engines Shop Manual…………….1002
SAFETY …………….1006
SAFETY NOTICE …………….1006
FOREWORD …………….1008
GENERAL …………….1008
STANDARD TIGHTENING TORQUE …………….1015
CONVERSION TABLE …………….1019
SPECIFICATIONS …………….1031
OVERALL DRAWING …………….1037
GENERAL STRUCTURE …………….1047
INTAKE AND EXHAUST SYSTEM …………….1049
AIR CLEANER …………….1053
CYLINDER …………….1066
MAIN CIRCULATION SYSTEM …………….1067
CRANKSHAFT …………….1071
CONNECTING ROD …………….1075
TIMING GEAR …………….1081
CAMSHAFT …………….1087
ROCKER ARM SHAFT, PUSH ROD AND TAPPET …………….1088
OIL PUMP …………….1091
OIL FILTER …………….1098
FUEL SYSTEM CHART …………….1100
FUEL INJECTION PUMP …………….1103
COOLING SYSTEM CHART …………….1114
WATER PUMP …………….1115
STARTING AND CHARGING SYSTEM ELECTRICAL CIRCUIT DIAGRAM …………….1121
ADJUSTING VALVE CLEARANCE …………….1129
MEASURING COMPRESSION PRESSURE …………….1131
ADJUSTING FUEL INJECTION PRESSURE ( CRACKING PRESSURE) …………….1132
PERFORMANCE TEST …………….1145
METHOD OF USING TROUBLESHOOTING CHARTS …………….1151
POINTS TO REMEMBER WHEN TROUBLESHOOTING …………….1155
TESTING AND ADJUSTING TOOL LIST …………….1174
SPECIAL TOOL LIST …………….1179
OVERALL DISASSEMBLY, ASSEMBLY …………….1180
DISASSEMBLY …………….1181
ASSEMBLY …………….1193
GRINDING CYLINDER HEAD MOUNTING SURFACE …………….1211
REPLACING VALVE GUIDE …………….1212
GRINDING VALVE …………….1213
REPLACING CAMSHAFT BUSHING …………….1214
REPLACING CRANKSHAFT GEAR …………….1216
REPLACING CAM GEAR …………….1217
REPLACING FLYWHEEL RING GEAR …………….1218
PROCEDURE FOR PRESSURE TEST …………….1219
CYLINDER LINER ( SPECIAL RESTORATION PART) …………….1220
MACHINING DRAWING FOR CYLINDER BLOCK BORE …………….1221
GRINDING CRANKSHAFT …………….1223
SEN04408-00 – 95 Series Diesel Engine Shop Manual…………….1226
SEN04408-00 WA65-6, WA70-6, WA80-6…………….1226
CONTENTS…………….1227
SAFETY…………….1227
FOREWORD…………….1229
01 GENERAL…………….1248
General…………….1249
General view…………….1251
4D95LWE-5…………….1251
S4D95LWE-5…………….1253
Specifications…………….1255
General assembly drawing…………….1257
4D95LWE-5 LEFT SIDE VIEW (WA65HH-6)…………….1257
4D95LWE-5 RIGHT SIDE VIEW (WA65HH-6)…………….1258
4D95LWE-5 FRONT VIEW (WA65HH-6)…………….1259
4D95LWE-5 REAR VIEW (WA65HH-6)…………….1260
S4D95LWE-5 LEFT SIDE VIEW (WA80HH-6)…………….1261
S4D95LWE-5 RIGHT SIDE VIEW (WA80HH-6)…………….1262
S4D95LWE-5 FRONT VIEW (WA80HH-6)…………….1263
S4D95LWE-5 REAR VIEW (WA80HH-6)…………….1264
DIMENSION TABLE…………….1265
Engine performance curve…………….1266
4D95LWE-5 [Applicable machine: WA65-HH-6]…………….1266
4D95LWE-5 [Applicable machine: WA70-HH-6]…………….1267
4D95LWE-5 [Applicable machine: WA80-HH-6]…………….1268
Weight table…………….1269
11 STRUCTURE AND FUNCTION…………….1270
General structure…………….1271
EXHAUST SYSTEM…………….1275
Turbocharger…………….1275
TD04L…………….1275
Outline of waste gate valve…………….1276
ENGINE BODY…………….1277
Cylinder head…………….1277
4D95LWE-5…………….1277
Cylinder head…………….1278
Head cover…………….1278
S4D95LWE-5…………….1279
Cylinder head…………….1280
Head cover…………….1280
Cylinder block…………….1281
Main moving parts…………….1283
Timing gear…………….1285
WITHOUT FRONT PTO TYPE (HELICAL GEAR)…………….1285
Front oil seal…………….1286
Valve system…………….1287
Flywheel and flywheel housing…………….1289
WITHOUT REAR PTO TYPE…………….1289
LUBRICATION SYSTEM…………….1291
Lubrication system chart…………….1291
Oil pump…………….1292
Specifications…………….1292
Oil pump…………….1292
Regulator valve…………….1292
Oil filter…………….1293
Relief valve…………….1293
FUEL SYSTEM…………….1294
Fuel system chart…………….1294
Fuel injection pump…………….1295
Fuel injection nozzle…………….1297
For direct fuel injection type…………….1297
For swirl chamber type…………….1297
Fuel injection nozzle…………….1297
COOLING STSTEM…………….1298
Cooling system chart…………….1298
Thermostat and fan drive…………….1299
THERMOSTAT (WITHOUT JIGGLE VALVE)…………….1301
ELECTRICAL SYSTEM…………….1302
Starting and charging system electrical circuit diagram…………….1302
Alternator…………….1303
ALTERNATOR WITH BUILT-IN REGULATOR (Open type, 90A)…………….1303
Starting motor…………….1305
For 2.2 kW…………….1305
Engine starting device…………….1306
GLOW PLUG (METAL 2-WIRE TYPE GLOW PLUG)…………….1306
1. Connector (round 8-pin), (Short 8-pin)…………….1307
2. Lead wire…………….1307
3. Case…………….1307
4. Bracket…………….1307
5. Label…………….1307
1. Water temperature sensor…………….1307
1. Glow relay…………….1307
2. Lead wire…………….1307
3. Connector (round 2-in)…………….1307
12 TESTING AND ADJUSTING…………….1308
Performance test…………….1309
Run-in standard…………….1309
Performance test criteria…………….1311
Testing and adjusting data…………….1313
Testing and adjusting tools list…………….1314
Intake and exhaust system…………….1315
Adjusting valve clearance…………….1315
Engine body…………….1317
Measuring compression pressure…………….1317
Measurement procedure…………….1317
Fuel system…………….1318
Adjusting fuel injection pressure (Cracking pressure)…………….1318
Shim data for adjusting injection pressure…………….1319
Testing and adjusting fuel injection timing…………….1320
Table of injection pumps using plunger with stepped lead…………….1325
Adjusting fuel injection rate…………….1326
Governor adjustment standard…………….1327
Troubleshooting…………….1330
Method of using troubleshooting charts…………….1331
Points on troubleshooting…………….1335
S-1 Starting performance is poor (Starting always takes time)…………….1336
S-2 Engine does not start…………….1337
1) Engine does not turn…………….1337
2) Engine turns but no exhaust gas comes out (Fuel is not being injected)…………….1338
3) Exhaust gas comes out but engine does not start (Fuel is being injected)…………….1339
S-3 Engine does not pick up smoothly (Follow-up is poor)…………….1340
S-4 Engine stops during operations…………….1341
S-5 Engine does not rotate smoothly…………….1342
S-6 Engine lacks output (no power)…………….1343
S-7 Exhaust gas is black (incomplete combustion)…………….1344
S-8 Oil consumption is excessive (or exhaust gas is blue)…………….1345
S-9 Oil becomes contaminated quickly…………….1346
S-10 Fuel consumption is excessive…………….1347
S-11 Oil is in coolant, or coolant spurts back, or coolant level goes down…………….1348
S-12 Oil pressure lamp lights up (drop in oil pressure)…………….1349
S-13 Oil level rises…………….1350
S-14 Coolant temperature becomes too high (overheating)…………….1351
S-15 Abnormal noise is made…………….1352
S-16 Vibration is excessive…………….1353
13 DISASSEMLY AND ASSEMBLY…………….1354
General disassembly…………….1355
Special tools…………….1355
General assembly…………….1367
Special tools…………….1367
14 MAINTENANCE STANDARD…………….1386
Turbocharger…………….1387
Cylinder head…………….1389
Valve, valve guide…………….1391
Rocker arm shaft, push rod and tappet…………….1392
Cylinder block…………….1393
Cylinder…………….1395
Crankshaft…………….1396
Camshaft…………….1397
Timing gear (Helical gear)…………….1399
Flywheel and flywheel housing…………….1400
Piston, piston ring and piston pin…………….1401
Connecting rod…………….1403
Regulator valve…………….1405
Water pump and thermostat…………….1406
15 REPAIR AND REPLACEMENT OF PARTS…………….1408
Grinding cylinder head mounting surface…………….1409
Replacing valve guide…………….1410
Special tools…………….1410
Grinding valve…………….1411
Special tool…………….1411
Replacing camshaft bushing…………….1412
Special tools…………….1412
Replacing crankshaft gear…………….1414
Testing and adjusting fuel injection timing…………….1415
Replacing flywheel ring gear…………….1416
Procedure for pressure test…………….1417
Special tools…………….1417
Cylinder liner…………….1418
(special restoration part)…………….1418
Cylinder liner…………….1418
Machining drawing for cylinder block bore…………….1419
Additional machining of cam journal…………….1420
Grinding crankshaft…………….1421
Applicable crankshaft…………….1421
Replacing connecting rod small end bushing…………….1422
Special tools…………….1422