Komatsu 95 Series Diesel Engine Workshop Manual
Comprehensive service documentation for 3D95S, 4D95L, S4D95L, 6D95L, S6D95L & SA6D95L engines with specifications, repair procedures, and maintenance standards.
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Models Covered & Key Technical Specifications
Komatsu 95 Series Diesel Engines (3D95S-W-1, 4D95L-1, 4D95S-W-1, 6D95L-1, S6D95L-1, SA6D95L-1) — 1998 Functional Engineering Documentation | Komatsu Series Module.
- Calibrated Displacement Data: Engine cylinder volumes range from 2,020 cc (3-cylinder) to 4,890 cc (6-cylinder) is specified as the total piston displacement Architecture.
- Measured Power Output: Maximum rated horsepower ranges from 35 HP to 118 HP depending on engine configuration delivers optimal performance Framework.
- Primary Torque Specification: Maximum torque output reaches 12.5–46.6 kgm at various engine speeds requires proper load management Standards.
- Specific Injection Equipment: Bosch PES-A type fuel injection pump is configured at centrifugal all-speed governor design Logic.
- Published Lubrication Data: Engine oil capacity is measured at 5.0–12.5 liters depending on model specification Margin.
- System Cooling Capacity: Coolant capacity reaches 9–22.3 liters establishing the thermal management Protocol.
Professional Workshop Service Manual & Technical Specifications
Applied Assembly Shop Manual: Komatsu 95 Series Diesel Engine Powertrain-Manual
Procedure-Type: 3D95S-W-1, 4D95L-1, 4D95L-W-1, 4D95S-W-1, S4D95L-1, S4D95LE-3, SAA4D95LE-3, 6D95L-1, S6D95L-1, SA6D95L-1 // Model-Designation: Direct fuel injection and swirl chamber diesel engines / In-line configurations Logic // Procedure-Type: 820 pages covering comprehensive service data with 14 major chapters.
| Component System | Documentation Scope | Reference Details |
|---|---|---|
| Engine Architecture | Cylinder block, crankshaft, camshaft, and piston assemblies | Complete specifications provided |
| Lubrication Network | Oil pump, filter, cooler, and distribution pathways | Chapter 11: Lubrication system procedures |
| Fuel Delivery | Injection pump calibration, nozzle pressures, and governor settings | See Chapter 12: Fuel system specifications |
| Thermal Management | Water pump, thermostat, radiator cooling circuits | Chapter 10: Cooling system data |
| Electrical Components | Alternator, starting motor, glow plug systems | Chapter 12: Electrical system wiring |
The repository is divided into general overviews, covering engine structure and function, testing procedures that validate combustion systems, disassembly and assembly sequences that govern component removal and installation, maintenance standards that establish inspection criteria, and repair and replacement guidance addressing component service requirements. Service sections detail intake and exhaust management including air cleaner operation and turbocharger function, complementing lubrication system arrangements and fuel injection pump calibration processes.
Precise Methodology
Methodically requiring attention to technical standards, the manual encompasses specifications for all engine model variants within the 95 Series family. The document addresses three-cylinder through six-cylinder configurations with detailed coverage of both precombustion chamber and direct fuel injection designs. Installation guidelines are provided for fuel injection systems, turbocharger assemblies, and coolant circulation networks across multiple machine applications from compact excavators to power generation equipment.
Comprehensive Architecture
The engine assembly documentation articulates camshaft-to-crankshaft timing relationships, piston ring configurations with hard-chrome plating specifications, and bearing material selections for primary and connecting rod journals. Maintenance guidelines are included for valve clearance adjustments specified in both hot and cold engine conditions, oil pressure monitoring across operating ranges, and coolant flow verification through all cooling passages. The manual documents torque specifications for bolt assemblies to ensure proper pivot-point integrity.
Engineered Parameters
OEM guidelines are included for fuel injection timing verification using both match-mark alignment and delivery valve methods applicable to different injection pump configurations. Technical data encompasses fuel consumption ratios measured in grams per horsepower-hour, governor performance curves demonstrating speed regulation across full operating ranges, and nozzle opening pressures calibrated between 120 and 225 kilograms per square centimeter depending on engine variant.
Advanced Nexus
Transmission service information covers coupling-type and flange-type fuel injection pump installations with specific adjustment procedures for engine stop motors and fuel cut solenoid clearances. The documentation includes electronic governor system control logic for alternator power generation applications, with circuit diagrams depicting load detection feedback systems and controller fault diagnosis protocols.
Systematic Parameters
HVAC system procedures are included for electrical intake air heater glow plug assemblies, with quick-glow controller wiring schematics and water temperature sensor calibration data. Comprehensive troubleshooting tables correlate symptom observations to probable causes across lubrication, cooling, fuel, electrical, and combustion systems, supporting systematic diagnostic methodology for field technicians and workshop service teams.
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