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SEN0440

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CONTENTS No. of page

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

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95 SERIES

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 k 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 grinding 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. 4. When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always inform 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. 5. Keep all tools in good condition and learn the them.

95 SERIES

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 smoking. Never smoke while working. PREPARATIONS FOR WORK 7. 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. 8. 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 warning 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

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 (–) 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 internal 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.

SAFETY NOTICE

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 being operated. 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. 21.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. 22.When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. 23.When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any measurements. 24.Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates suddenly, so never let anyone stand at either end of the track.

16.When removing components, be careful not to break or damage the wiring. Damaged wiring may cause electrical fires. 17.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. 18.As a general rule, do not use gasoline to wash parts. In particular, use only the minimum of gasoline when washing electrical parts.

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95 SERIES

FOREWORD

GENERAL

FOREWORD GENERAL This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.

This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.

STRUCTURE AND FUNCTION This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards. TESTING AND ADJUSTING This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating "Problems" with "Causes" are also included in this section. DISASSEMBLY AND ASSEMBLY This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them. MAINTENANCE STANDARD This section gives the judgment standards for inspection of disassembled parts. The contents of this section may be described in STRUCTURE AND FUNCTION. OTHERS This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. In addition, this section may give the specifications of attachments and options together.

NOTICE The specifications contained in this shop manual are subject to change at any time and without any advance notice. Use the specifications given in the book with the latest date.

95 SERIES

00-5

FOREWORD

HOW TO READ THE SHOP MANUAL

REVISED EDITION MARK

VOLUMES Shop manuals are issued as a guide to carrying out repairs. They are divided as follows:

When a manual is revised, an edition mark ((1)(2)(3)....) is recorded on the bottom of the pages.

Chassis volume: Issued for every machine model Engine volume: Issued for each engine series Each issued as one Electrical volume: Attachments volume: · volume to cover all models

REVISIONS

}

These various volumes are designed to avoid duplicating the same information. Therefore, to deal with all repairs for any model , it is necessary that chassis, engine, electrical and attachment volumes be available. DISTRIBUTION AND UPDATING Any additions, amendments or other changes will be sent to KOMATSU distributors. Get the most up-todate information before you start any work.

FILING METHOD 1. See the page number on the bottom of the page. File the pages in correct order. 2. Following examples show how to read the page number. Example 1 (Chassis volume): 10 - 3 Item number (10. Structure and Function) Consecutive page number for each item. Example 2 (Engine volume): 12 - 5 Unit number (1. Engine) Item number (2. Testing and Adjusting) Consecutive page number for each item. 3. Additional pages: Additional pages are indicated by a hyphen (-) and number after the page number. File as in the example. Example: 12-203 10-4 12-203-1 10-4-1 Added pages 12-203-2 10-4-2 12-204 10-5

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Revised pages are shown in the LIST OF REVISED PAGES next to the CONTENTS page.

SYMBOLS So that the shop manual can be of ample practical use, important safety and quality portions are marked with the following symbols.

Symbol

Item

Remarks

Safety

Special safety precautions are necessary when performing the work.

Caution

Special technical precautions or other precautions for preserving standards are necessary when performing the work.

Weight

Weight of parts of systems. Caution necessary when selecting hoisting wire, or when working posture is important, etc.

Tightening torque

Places that require special attention for the tightening torque during assembly.

Coat

Places to be coated with adhesives and lubricants, etc.

Oil, water

Places where oil, water or fuel must be added, and the capacity.

Drain

Places where oil or water m u s t b e d r a i n ed , a n d quantity to be drained.

3 2

95 SERIES

FOREWORD

HOISTING INSTRUCTIONS

HOISTING INSTRUCTIONS HOISTING k Heavy parts (25 kg or more) must be lifted with a hoist, etc. In the DISASSEMBLY AND ASSEMBLY section, every part weighing 25 kg or more is indicated clearly with the symbol 4 •

If a part cannot be smoothly removed from the machine by hoisting, the following checks should be made: 1) Check for removal of all bolts fastening the part to the relative parts. 2) Check for existence of another part causing interference with the part to be removed.

WIRE ROPES 1) Use adequate ropes depending on the weight of parts to be hoisted, referring to the table below: Wire ropes (Standard "Z" or "S" twist ropes without galvanizing) Rope diameter

Allowable load

tons

10 11.5 12.5 14 16 18 20 22.4 30 40 50 60

9.8 13.7 15.7 21.6 27.5 35.3 43.1 54.9 98.1 176.5 274.6 392.2

1.0 1.4 1.6 2.2 2.8 3.6 4.4 5.6 10.0 18.0 28.0 40.0

Slinging near the edge of the hook may cause the rope to slip off the hook during hoisting, and a serious accident can result. Hooks have maximum strength at the middle portion.

100%

88%

79%

71%

41% SAD00479

3) Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound onto the load.

k Slinging with one rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident.

4) Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with two or more ropes, the force subjected to each rope will increase with the hanging angles. The table below shows the variation of allowable load kN {kg} when hoisting is made with two ropes, each of which is allowed to sling up to 9.8 kN {1000 kg} vertically, at various hanging angles. When two ropes sling a load vertically, up to 19.6 kN {2000 kg} of total weight can be suspended. This weight becomes 9.8 kN {1000 kg} when two ropes make a 120° hanging angle. On the other hand, two ropes are subjected to an excessive force as large as 39.2 kN {4000 kg} if they sling a 19.6 kN {2000 kg} load at a lifting angle of 150°.

★ The allowable load value is estimated to be onesixth or one-seventh of the breaking strength of the rope used. 2) Sling wire ropes from the middle portion of the hook.

95 SERIES

00-7

FOREWORD

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER k Before carrying out the following work, release the residual pressure from the hydraulic tank. For details, see TESTING AND ADJUSTING, Releasing residual pressure from hydraulic tank.

Type 1

k Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out when the hose is disconnected. Accordingly, prepare an oil receiving container. Disconnection 1) Release the residual pressure from the hydraulic tank. For details, see TESTING AND ADJUSTING, Releasing residual pressure from hydraulic tank. 2) Hold adapter (1) and push hose joint (2) into mating adapter (3). (See Fig. 1) ★ The adapter can be pushed in about 3.5 mm. ★ Do not hold rubber cap portion (4). 3) After hose joint (2) is pushed into adapter (3), press rubber cap portion (4) against (3) until it clicks. (See Fig. 2) 4) Hold hose adapter (1) or hose (5) and pull it out. (See Fig. 3) ★ Since some hydraulic oil flows out, prepare an oil receiving container. Connection 1) Hold hose adapter (1) or hose (5) and insert it in mating adapter (3), aligning them with each other. (See Fig. 4) ★ Do not hold rubber cap portion (4). 2) After inserting the hose in the mating adapter perfectly, pull it back to check its connecting condition. (See Fig. 5) ★ When the hose is pulled back, the rubber cap portion moves toward the hose about 3.5 mm. This does not indicate abnormality, however.

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95 SERIES

FOREWORD

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

Type 3

1) Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end.

2) Hold in the condition in Step 1), and turn lever (4) to the right (clockwise).

2) Hold in the condition in Step 1), and push until cover (3) contacts contact surface a of the hexagonal portion at the male end.

3) Hold in the condition in Steps 1) and 2), and pull out whole body (2) to disconnect it.

•

Disassembly

Type 2

Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end to connect it.

Connection

Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end to connect it.

95 SERIES

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FOREWORD

COATING MATERIALS

COATING MATERIALS ★ The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly and assembly are listed below. ★ For coating materials not listed below, use the equivalent of products shown in this list. Category

Komatsu code

Part No.

LT-1A

790-129-9030

LT-1B

790-129-9050

LT-2

09940-00030

LT-3

790-129-9060 (Set of adhesive and hardening agent)

LT-4

790-129-9040

Holtz MH 705

790-126-9120

Three bond 1735

790-129-9140

Aron-alpha 201

790-129-9130

Loctite 648-50

79A-129-9110

LG-1

790-129-9010

LG-5

790-129-9080

LG-6

790-129-9020

LG-7

790-129-9070

Three bond 1211

790-129-9090

Three bond 1207B

419-15-18131

Adhesives

Gasket sealant

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Q’ty

Container

Main applications, features

• Used to prevent rubber gaskets, rubber cushions, and cock plug from coming out. • Used in places requiring an immediately effective, strong adhesive. Used for plastics (except polyethylene, 20 g Polyethylene polyprophylene, tetrafluoroethlene and (2 pcs.) container vinyl chloride), rubber, metal and nonmetal. • Features: Resistance to heat and chemicals Polyethylene 50 g • Used for anti-loosening and sealant container purpose for bolts and plugs. • Used as adhesive or sealant for metal, Adhesive: glass and plastic. 1 kg Hardening Can agent: 500 g Polyethylene • Used as sealant for machined holes. 250 g container • Used as heat-resisting sealant for 75 g Tube repairing engine. • Quick hardening type adhesive Polyethylene • Cure time: within 5 sec. to 3 min. 50 g container • Used mainly for adhesion of metals, rubbers, plastics and woods. • Quick hardening type adhesive • Quick cure type Polyethylene (max. strength after 30 minutes) 2g container • Used mainly for adhesion of rubbers, plastics and metals. • Resistance to heat, chemicals Polyethylene • Used at joint portions subject to high 50 cc container temperatures. • Used as adhesive or sealant for gaskets 200 g Tube and packing of power train case, etc. • Used as sealant for various threads, pipe joints, flanges. 1 kg Can • Used as sealant for tapered plugs, elbows, nipples of hydraulic piping. • Features: Silicon based, resistance to heat, cold 200 g Tube • Used as sealant for flange surface, tread. • Used as sealant for oil pan, final drive case, etc. • Features: Silicon based, quick hardening type • Used as sealant for flywheel housing, 1 kg Tube intake manifold, oil pan, thermostat housing, etc. • Used as heat-resisting sealant for 100 g Tube repairing engine. • Features: Silicone type, heat resistant, vibration resistant, and impact resistant 100 g Tube sealing material • Used as sealing material for transfer case 150 g

Tube

95 SERIES

FOREWORD

Molybdenum disulphide lubricant

Komatsu code

Part No.

Q’ty

Container

LM-G

09940-00051

60 g

Can

LM-P

09940-00040

200 g

Tube

Various

G2-LI

G2-CA

Grease

Primer

Caulking material

95 SERIES

Various

Molybdenum SYG2-400M 400 g × 10 Bellows type disulphide SYG2-400M-A 400 g × 20 Bellows type grease SYGA-16CNM 16 kg Can LM-G (G2-M) Hyper White SYG2-400T-A Grease G2-T SYG2-16CNT 400 g Bellows type G0-T (*) SYG0-400T-A (*) 16 kg Can *: For use in SYG0-16CNT (*) cold district Biogrease G2B SYG2-400B G2-BT (*) 400 g Bellows type SYGA-16CNB *: For high 16 kg Can SYG2-400BT (*) temperature SYGA-16CNBT (*) and large load SUNSTAR Glass PAINT PRIMER 20 ml container 580 SUPER 417-926-3910 SUNSTAR Glass GLASS PRIMER 20 ml container 580 SUPER SUNSTAR Glass 22M-54-27230 20 ml PAINT PRIMER container 435-95 SUNSTAR GLASS PRIMER 435-41

Adhesive

SYG2-400LI SYG2-350LI SYG2-400LI-A SYG2-160LI SYGA-160CNLI SYG2-400CA SYG2-350CA SYG2-400CA-A SYG2-160CA SYGA-160CNCA

SUNSTAR SASH PRIMER GP-402 SUNSTAR PENGUINE SUPER 560 SUNSTAR PENGUINE SEAL 580 SUPER “S” or “W” Sika Japan, Sikaflex 256HV SUNSTAR PENGUINE SEAL No. 2505 SEKISUI SILICONE SEALANT GE TOSHIBA SILICONES TOSSEAL 381

22M-54-27240

150 ml

Can

22M-54-27250

20 ml

Glass container

22M-54-27210

320 ml

Ecocart (Special container)

417-926-3910

320 ml

Polyethylene container

20Y-54-39850

310 ml

Polyethylene container

417-926-3920

320 ml

Polyethylene container

20Y-54-55130

333 ml

Polyethylene container

22M-54-27220

333 ml

Cartridge

Main applications, features • Used as lubricant for sliding portion (to prevent from squeaking). • Used to prevent seizure or scuffling of the thread when press fitting or shrink fitting. • Used as lubricant for linkage, bearings, etc. • General purpose type

• Used for normal temperature, light load bearing at places in contact with water or steam.

• Used for heavy load portion

• Seizure resistance and heat resistance higher than molybdenum disulfide grease • Since this grease is white, it does not stand out against machine body. • Since this grease is decomposed by bacteria in short period, it has less effects on microorganisms, animals, and plants.

• Used as primer for cab side (Using limit: 4 months) • Used as primer for glass side (Using limit: 4 months)

Adhesive for cab glass

Category

COATING MATERIALS

• Used as primer for painted surface on cab side (Using limit: 4 months) • Used as primer for black ceramiccoated surface on glass side and for hard polycarbonate-coated surface (Using limit: 4 months) • Used as primer for sash (Alumite). (Using limit: 4 months) • Used as adhesive for glass. (Using limit: 6 months) • “S” is used for high-temperature season (April - October) and “W” for low-temperature season (November April) as adhesive for glass. (Using limit: 4 months) • Used as adhesive for glass. (Using limit: 6 months) • Used to seal joints of glass parts. (Using limit: 4 months) • Used to seal front window. (Using limit: 6 months) • Used to seal joint of glasses. Translucent white seal. (Using limit: 12 months)

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FOREWORD

STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH) ★ In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in the table below. Tightening torque Thread diameter of bolt

Width across flats

kgm

6 8 10 12 14

10 13 17 19 22

11.8 – 14.7 27 – 34 59 – 74 98 – 123 153 – 190

1.2 – 1.5 2.8 – 3.5 6 – 7.5 10 – 12.5 15.5 – 19.5

16 18 20 22 24

24 27 30 32 36

235 – 285 320 – 400 455 – 565 610 – 765 785 – 980

23.5 – 29.5 33 – 41 46.5 – 58 62.5 – 78 80 – 100

27 30 33 36 39

41 46 50 55 60

1150 – 1440 1520 – 1910 1960 – 2450 2450 – 3040 2890 – 3630

118 – 147 155 – 195 200 – 250 250 – 310 295 – 370

Thread diameter of bolt

Width across flats

kgm

6 8 10 12

10 13 14 27

5.9 – 9.8 13.7 – 23.5 34.3 – 46.1 74.5 – 90.2

0.6 – 1.0 1.4 – 2.4 3.5 – 4.7 7.6 – 9.2

Tightening torque

Sealing surface

TABLE OF TIGHTENING TORQUES FOR FLARED NUTS ★ In the case of flared nuts for which there is no special instruction, tighten to the torque given in the table below.

SAD00483

Thread diameter

Width across flat

kgm

14 18 22 24 30 33 36 42

19 24 27 32 36 41 46 55

24.5 ± 4.9 49 ± 19.6 78.5 ± 19.6 137.3 ± 29.4 176.5 ± 29.4 196.1 ± 49 245.2 ± 49 294.2 ± 49

2.5 ± 0.5 5±2 8±2 14 ± 3 18 ± 3 20 ± 5 25 ± 5 30 ± 5

00-12

Tightening torque

95 SERIES

FOREWORD

STANDARD TIGHTENING TORQUE

TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS ★ In the case of split flange bolts for which there is no special instruction, tighten to the torque given in the table below.

Thread diameter

Width across flat

Tightening torque

kgm

10 12 16

14 17 22

59 – 74 98 – 123 235 – 285

6 – 7.5 10 – 12.5 23.5 – 29.5

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS ★ Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.

Thread diameter

Width across flat

Tightening torque (Nm {kgm})

Range

Target

14 20 24 33 42

Varies depending on type of connector.

35 – 63 {3.5 – 6.5} 84 – 132 {8.5 – 13.5} 128 – 186 {13.0 – 19.0} 363 – 480 {37.0 – 49.0} 746 – 1010 {76.0 – 103}

44 {4.5} 103 {10.5} 157 {16.0} 422 {43.0} 883 {90.0}

Norminal No.

02 03, 04 05, 06 10, 12 14

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS ★ Unless there are special instructions, tighten the O-ring boss plugs to the torque below.

Thread diameter

Width across flat

Tightening torque (Nm {kgm})

Range

Target

08 10 12 14 16 18 20 24 30 33 36 42 52

14 17 19 22 24 27 30 32 32 — 36 — —

5.88 – 8.82 {0.6 – 0.9} 9.8 – 12.74 {1.0 – 1.3} 14.7 – 19.6 {1.5 – 2.0} 19.6 – 24.5 {2.0 – 2.5} 24.5 – 34.3 {2.5 – 3.5} 34.3 – 44.1 {3.5 – 4.5} 44.1 – 53.9 {4.5 – 5.5} 58.8 – 78.4 {6.0 – 8.0} 93.1 – 122.5 {9.5 – 12.5} 107.8 – 147.0 {11.0 – 15.0} 127.4 – 176.4 {13.0 – 18.0} 181.3 – 240.1 {18.5 – 24.5} 274.4 – 367.5 {28.0 – 37.5}

7.35 {0.75} 11.27 {1.15} 17.64 {1.8} 22.54 {2.3} 29.4 {3.0} 39.2 {4.0} 49.0 {5.0} 68.6 {7.0} 107.8 {11.0} 124.4 {13.0} 151.9 {15.5} 210.7 {21.5} 323.4 {33.0}

Norminal No.

08 10 12 14 16 18 20 24 30 33 36 42 52

95 SERIES

00-13

FOREWORD

STANDARD TIGHTENING TORQUE

TIGHTENING TORQUE FOR 102 AND 114 ENGINE SERIES 1) BOLT AND NUTS Use these torques for bolts and nuts (unit: mm) of Cummins Engine. Thread diameter

Tightening torque

kgm

6 8 10 12

10 ± 2 24 ± 4 43 ± 6 77 ± 12

1.02 ± 0.20 2.45 ± 0.41 4.38 ± 0.61 7.85 ± 1.22

2) EYE JOINTS Use these torques for eye joints (unit: mm) of Cummins Engine. Thread diameter

Tightening torque

kgm

6 8 10 12 14

8±2 10 ± 2 12 ± 2 24 ± 4 36 ± 5

0.81 ± 0.20 1.02 ± 0.20 1.22 ± 0.20 2.45 ± 0.41 3.67 ± 0.51

3) TAPERED SCREWS Use these torques for tapered screws (unit: inch) of Cummins Engine. Thread diameter

Tightening torque

inch

kgm

1 / 16 1/8 1/4 3/8 1/2 3/4 1

3±1 8±2 12 ± 2 15 ± 2 24 ± 4 36 ± 5 60 ± 9

0.31 ± 0.10 0.81 ± 0.20 1.22 ± 0.20 1.53 ± 0.20 2.45 ± 0.41 3.67 ± 0.51 6.12 ± 0.92

TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE) ★ Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified. ★ Apply the following torque when the threads are coated (wet) with engine oil. Tightening torque (Nm {kgm}) Nominal size Width across of hose flats

Taper seal type

Face seal type

Thread size Nominal thread Root diameter size - Threads per (mm) (Reference) (mm) inch, Thread series

Range

Target

34 – 54 {3.5 – 5.5}

44 {4.5}

–

9 — – 18UN 16

14.3

34 – 63 {3.5 – 6.5}

44 {4.5}

–

54 – 93 {5.5 – 9.5}

74 {7.5}

–

11 — – 16UN 16

17.5

59 – 98 {6.0 – 10.0}

78 {8.0}

–

84 – 132 {8.5 – 13.5}

103 {10.5}

13 — – 16UN 16

20.6

128 – 186 {13.0 – 19.0}

157 {16.0}

1 – 14UNS

25.4

177 – 245 {18.0 – 25.0}

216 {22.0}

3 1 — – 12UN 16

30.2

(10)

177 – 245 {18.0 – 25.0}

216 {22.0}

–

(12)

197 – 294 {20.0 – 30.0}

245 {25.0}

–

(14)

246 – 343 {25.0 – 35.0}

294 {30.0}

–

00-14

95 SERIES

FOREWORD

ELECTRIC WIRE CODE

ELECTRIC WIRE CODE In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. This wire code table will help you understand WIRING DIAGRAMS. Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.

CLASSIFICATION BY THICKNESS Copper wire Cable O.D. (mm)

Current rating (A)

Applicable circuit

0.88

2.4

Starting, lighting, signal etc.

0.32

2.09

3.1

Lighting, signal etc.

0.32

5.23

4.6

Charging and signal

0.45

13.36

7.0

Starting (Glow plug)

0.80

42.73

11.4

135

Starting

127

0.80

63.84

13.6

178

Starting

100

217

0.80

109.1

17.6

230

Starting

Norminal number

Number of strands

Dia. of strands (mm2)

Cross section (mm2)

0.85

0.32

CLASSIFICATION BY COLOR AND CODE Circuits Priority Classification

Primary

Charging

Ground

Starting

Lighting

Instrument

Signal

Other

Code

Color

White

Black

Red

Yellow

Green

Blue

Code

—

2 Color White & Red

—

Code

—

White & Black Red & White Rellow & Red Green & White Blue & White BY

Auxiliary

Color White & Black

—

Code

—

Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow BR

Color White & Blue

—

Code

—

Color White & Green

—

Code

—

Color

—

Black & Red Red & Yellow RG

Yellow & Green

Green & Yellow

Blue & Yellow

5 Red & Green Yellow & Blue Green & Black Blue & Black RL

—

95 SERIES

Red & Blue Yellow & White Green & Blue

—

00-15

FOREWORD

CONVERSION TABLE

CONVERSION TABLE METHOD OF USING THE CONVERSION TABLE The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the Conversion Table, see the example given below.

EXAMPLE • Method of using the Conversion Table to convert from millimeters to inches 1. Convert 55 mm into inches. (1) Locate the number 50 in the vertical column at the left side, take this as (A), then draw a horizontal line from (A). (2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down from (B). (3) Take the point where the two lines cross as (C). This point (C) gives the value when converting from millimeters to inches. Therefore, 55 mm = 2.165 inches. 2. Convert 550 mm into inches. (1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the left) to convert it to 55 mm. (2) Carry out the same procedure as above to convert 55 mm to 2.165 inches. (3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches. (B) Millimeters to inches 1 mm = 0.03937 in

(A)

00-16

0 10 20 30 40

0 0.394 0.787 1.181 1.575

0.039 0.433 0.827 1.220 1.614

0.079 0.472 0.866 1.260 1.654

0.118 0.512 0.906 1.299 1.693

0.157 0.551 0.945 1.339 1.732

0.236 0.630 1.024 1.417 1.811

0.276 0.669 1.063 1.457 1.850

0.315 0.709 1.102 1.496 1.890

0.354 0.748 1.142 1.536 1.929

50 60 70 80 90

1.969 2.362 2.756 3.150 3.543

2.008 2.402 2.795 3.189 3.583

2.047 2.441 2.835 3.228 3.622

2.087 2.480 2.874 3.268 3.661

2.126 2.520 2.913 3.307 3.701

0.197 0.591 0.984 1.378 1.772 (C) 2.165 2.559 2.953 3.346 3.740

2.205 2.598 2.992 3.386 3.780

2.244 2.638 3.032 3.425 3.819

2.283 2.677 3.071 3.465 3.858

2.323 2.717 3.110 3.504 3.898

95 SERIES

FOREWORD

CONVERSION TABLE

Millimeters to Inches 1 mm = 0.03937 in

0.039

0.079

0.118

0.157

0.197

0.236

0.276

0.315

0.354

0.394

0.433

0.472

0.512

0.551

0.591

0.630

0.669

0.709

0.748

0.787

0.827

0.866

0.906

0.945

0.984

1.024

1.063

1.102

1.142

1.181

1.220

1.260

1.299

1.339

1.378

1.417

1.457

1.496

1.536

1.575

1.614

1.654

1.693

1.732

1.772

1.811

1.850

1.890

1.929

1.969

2.008

2.047

2.087

2.126

2.165

2.205

2.244

2.283

2.323

2.362

2.402

2.441

2.480

2.520

2.559

2.598

2.638

2.677

2.717

2.756

2.795

2.835

2.874

2.913

2.953

2.992

3.032

3.071

3.110

3.150

3.189

3.228

3.268

3.307

3.346

3.386

3.425

3.465

3.504

3.543

3.583

3.622

3.661

3.701

3.740

3.780

3.819

3.858

3.898

Kilogram to Pound 1 kg = 2.2046 lb

2.20

4.41

6.61

8.82

11.02

13.23

15.43

17.64

19.84

22.05

24.25

26.46

28.66

30.86

33.07

35.27

37.48

39.68

41.89

44.09

46.30

48.50

50.71

51.91

55.12

57.32

59.53

61.73

63.93

66.14

68.34

70.55

72.75

74.96

77.16

79.37

81.57

83.78

85.98

88.18

90.39

92.59

94.80

97.00

99.21

101.41

103.62

105.82

108.03

110.23

112.44

114.64

116.85

119.05

121.25

123.46

125.66

127.87

130.07

132.28

134.48

136.69

138.89

141.10

143.30

145.51

147.71

149.91

152.12

154.32

156.53

158.73

160.94

163.14

165.35

167.55

169.76

171.96

174.17

176.37

178.57

180.78

182.98

185.19

187.39

189.60

191.80

194.01

196.21

198.42

200.62

202.83

205.03

207.24

209.44

211.64

213.85

216.05

218.26

95 SERIES

00-17

FOREWORD

CONVERSION TABLE

Liter to U.S. Gallon 1l = 0.2642 U.S. Gal

0.264

0.528

0.793

1.057

1.321

1.585

1.849

2.113

2.378

2.642

2.906

3.170

3.434

3.698

3.963

4.227

4.491

4.755

5.019

5.283

5.548

5.812

6.076

6.340

6.604

6.869

7.133

7.397

7.661

7.925

8.189

8.454

8.718

8.982

9.246

9.510

9.774

10.039

10.303

10.567

10.831

11.095

11.359

11.624

11.888

12.152

12.416

12.680

12.944

13.209

13.473

13.737

14.001

14.265

14.529

14.795

15.058

15.322

15.586

15.850

16.115

16.379

16.643

16.907

17.171

17.435

17.700

17.964

18.228

18.492

18.756

19.020

19.285

19.549

19.813

20.077

20.341

20.605

20.870

21.134

21.398

21.662

21.926

22.190

22.455

22.719

22.983

23.247

23.511

23.775

24.040

24.304

24.568

24.832

25.096

25.361

25.625

25.889

26.153

Liter to U.K. Gallon 1l = 0.21997 U.K. Gal

0.220

0.440

0.660

0.880

1.100

1.320

1.540

1.760

1.980

2.200

2.420

2.640

2.860

3.080

3.300

3.520

3.740

3.950

4.179

4.399

4.619

4.839

5.059

5.279

5.499

5.719

5.939

6.159

6.379

6.599

6.819

7.039

7.259

7.479

7.969

7.919

8.139

8.359

8.579

8.799

9.019

9.239

9.459

9.679

9.899

10.119

10.339

10.559

10.778

10.998

11.281

11.438

11.658

11.878

12.098

12.318

12.528

12.758

12.978

13.198

13.418

13.638

13.858

14.078

14.298

14.518

14.738

14.958

15.178

15.398

15.618

15.838

16.058

16.278

16.498

16.718

16.938

17.158

17.378

17.598

17.818

18.037

18.257

18.477

18.697

18.917

19.137

19.357

19.577

19.797

20.017

20.237

20.457

20.677

20.897

21.117

21.337

21.557

21.777

00-18

95 SERIES

FOREWORD

CONVERSION TABLE

kgm to ft. lb 1 kgm = 7.233 ft. lb

7.2

14.5

21.7

28.9

36.2

43.4

50.6

57.9

65.1

72.3

79.6

86.8

94.0

101.3

108.5

115.7

123.0

130.2

137.4

144.7

151.9

159.1

166.4

173.6

180.8

188.1

195.3

202.5

209.8

217.0

224.2

231.5

238.7

245.9

253.2

260.4

267.6

274.9

282.1

289.3

296.6

303.8

311.0

318.3

325.5

332.7

340.0

347.2

354.4

361.7

368.9

376.1

383.4

390.6

397.8

405.1

412.3

419.5

426.8

434.0

441.2

448.5

455.7

462.9

470.2

477.4

484.6

491.8

499.1

506.3

513.5

520.8

528.0

535.2

542.5

549.7

556.9

564.2

571.4

578.6

585.9

593.1

600.3

607.6

614.8

622.0

629.3

636.5

643.7

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

95 SERIES

00-19

FOREWORD

CONVERSION TABLE

kg/cm2 to lb/in2 1kg/cm2 = 14.2233 lb/in2

14.2

28.4

42.7

56.9

71.1

85.3

99.6

113.8

128.0

142.2

156.5

170.7

184.9

199.1

213.4

227.6

241.8

256.0

270.2

284.5

298.7

312.9

327.1

341.4

355.6

369.8

384.0

398.3

412.5

426.7

440.9

455.1

469.4

483.6

497.8

512.0

526.3

540.5

554.7

568.9

583.2

597.4

611.6

625.8

640.1

654.3

668.5

682.7

696.9

711.2

725.4

739.6

753.8

768.1

782.3

796.5

810.7

825.0

839.2

853.4

867.6

881.8

896.1

910.3

924.5

938.7

953.0

967.2

981.4

995.6

1010

1024

1038

1053

1067

1081

1095

1109

1124

1138

1152

1166

1181

1195

1209

1223

1237

1252

1266

1280

1294

1309

1323

1337

1351

1365

1380

1394

1408

100

1422

1437

1451

1465

1479

1493

1508

1522

1536

1550

110

1565

1579

1593

1607

1621

1636

1650

1664

1678

1693

120

1707

1721

1735

1749

1764

1778

1792

1806

1821

1835

130

1849

1863

1877

1892

1906

1920

1934

1949

1963

1977

140

1991

2005

2020

2034

2048

2062

2077

2091

2105

2119

150

2134

2148

2162

2176

2190

2205

2219

2233

2247

2262

160

2276

2290

2304

2318

2333

2347

2361

2375

2389

2404

170

2418

2432

2446

2460

2475

2489

2503

2518

2532

2546

180

2560

2574

2589

2603

2617

2631

2646

2660

2674

2688

190

2702

2717

2731

2745

2759

2773

2788

2802

2816

2830

200

2845

2859

2873

2887

2901

2916

2930

2944

2958

2973

210

2987

3001

3015

3030

3044

3058

3072

3086

3101

3115

220

3129

3143

3158

3172

3186

3200

3214

3229

3243

3257

230

3271

3286

3300

3314

3328

3343

3357

3371

3385

3399

240

3414

3428

3442

3456

3470

3485

3499

3513

3527

3542

00-20

95 SERIES

FOREWORD

CONVERSION TABLE

Temperature Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface column of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left. If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right. 1°C = 33.8°F

°C

°F

°C

°F

°C

°F

°C

°F

–40.4 –37.2 –34.4 –31.7 –28.9

–40 –35 –30 –25 –20

–40.0 –31.0 –22.0 –13.0 –4.0

–11.7 –11.1 –10.6 –10.0 –9.4

11 12 13 14 15

51.8 53.6 55.4 57.2 59.0

7.8 8.3 8.9 9.4 10.0

46 47 48 49 50

114.8 116.6 118.4 120.2 122.0

27.2 27.8 28.3 28.9 29.4

81 82 83 84 85

117.8 179.6 181.4 183.2 185.0

–28.3 –27.8 –27.2 –26.7 –26.1

–19 –18 –17 –16 –15

–2.2 –0.4 1.4 3.2 5.0

–8.9 –8.3 –7.8 –7.2 –6.7

16 17 18 19 20

60.8 62.6 64.4 66.2 68.0

10.6 11.1 11.7 12.2 12.8

51 52 53 54 55

123.8 125.6 127.4 129.2 131.0

30.0 30.6 31.1 31.7 32.2

86 87 88 89 90

186.8 188.6 190.4 192.2 194.0

–25.6 –25.0 –24.4 –23.9 –23.3

–14 –13 –12 –11 –10

6.8 8.6 10.4 12.2 14.0

–6.1 –5.6 –5.0 –4.4 –3.9

21 22 23 24 25

69.8 71.6 73.4 75.2 77.0

13.3 13.9 14.4 15.0 15.6

56 57 58 59 0

132.8 134.6 136.4 138.2 140.0

32.8 33.3 33.9 34.4 35.0

91 92 93 94 95

195.8 197.6 199.4 201.2 203.0

–22.8 –22.2 –21.7 –21.1 –20.6

–9 –8 –7 –6 –5

15.8 17.6 19.4 21.2 23.0

–3.3 –2.8 –2.2 –1.7 –1.1

26 27 28 29 30

78.8 80.6 82.4 84.2 86.0

16.1 16.7 17.2 17.8 18.3

61 62 63 64 65

141.8 143.6 145.4 147.2 149.0

35.6 36.1 36.7 37.2 37.8

96 97 98 99 100

204.8 206.6 208.4 210.2 212.0

–20.0 –19.4 –18.9 –18.3 –17.8

–4 –3 –2 –1 0

24.8 26.6 28.4 30.2 32.0

–0.6 0 0.6 1.1 1.7

31 32 33 34 35

87.8 89.6 91.4 93.2 95.0

18.9 19.4 20.0 20.6 21.1

66 67 68 69 70

150.8 152.6 154.4 156.2 158.0

40.6 43.3 46.1 48.9 51.7

105 110 115 120 125

221.0 230.0 239.0 248.0 257.0

–17.2 –16.7 –16.1 –15.6 –15.0

1 2 3 4 5

33.8 35.6 37.4 39.2 41.0

2.2 2.8 3.3 3.9 4.4

36 37 38 39 40

96.8 98.6 100.4 102.2 104.0

21.7 22.2 22.8 23.3 23.9

71 72 73 74 75

159.8 161.6 163.4 165.2 167.0

54.4 57.2 60.0 62.7 65.6

130 135 140 145 150

266.0 275.0 284.0 293.0 302.0

–14.4 –13.9 –13.3 –12.8 –12.2

6 7 8 9 10

42.8 44.6 46.4 48.2 50.0

5.0 5.6 6.1 6.7 7.2

41 42 43 44 45

105.8 107.6 109.4 111.2 113.0

24.4 25.0 25.6 26.1 26.7

76 77 78 79 80

168.8 170.6 172.4 174.2 176.0

68.3 71.1 73.9 76.7 79.4

155 160 165 170 175

311.0 320.0 329.0 338.0 347.0

95 SERIES

00-21

SAFETY

UNITS

UNITS In this manual, the measuring units are indicated with Internatinal System of units (SI). As for reference, conventionally used Gravitational System of units are indicated in parentheses {

Example: N {kg} Nm {kgm} MPa {kg/cm2} kPa {mmH2O} kPa {mmHg} kW/rpm {HP/rpm} g/kWh {g/HPh}

00-22

95 SERIES

01 GENERAL General......................................................................................................................................................... 01- 2 General view................................................................................................................................................. 01- 4 Specifications................................................................................................................................................ 01- 8 General assembly drawing ........................................................................................................................... 01- 10 Engine performance curve ........................................................................................................................... 01- 19 Weight table.................................................................................................................................................. 01- 22

95 SERIES

01-1

GENERAL

GENERAL 1. Applicable machine Engine

Engine serial No.

Machine models

4D95LWE-5

WA65-HH-6 WA70-HH-6

S4D95LWE-5

WA80-HH-6

01-2

Wheel loader

95 SERIES

GENERAL

2. Outline of swirl chamber type engine •

•

The (S)4D95LWE-5 engine clears strict exhaust gas regulations (EPA Regulations of USA and Regulations of EU) and attained a small size, light weight, high output, low noise, improved gas color, high reliability and high durability, and is suitable various construction machinery and industrial machinery. The (S)4D95LWE-5 engine is an in-line, vertical, water-cooled, swirl chamber type, 4-cycle diesel engine, which has the following features. (1) Small-sized and light-weight engine • Since no liners are used in the engine block, the distance between the cylinders is reduced by the thickness of the liners, thus the overall length of the engine is reduced. • The stroke bore ratio is as large as 115 mm/95 mm. The overall height of the engine is reduced, however, by reducing the distance between the big end center and small end center of the connecting rod. • The heads of the cylinder head and cylinder block are thinned and light-weighted but their strength is maintained. • Each part is designed economically for weight reduction by applying reliability analysis technologies. (2) High-performance engine • Combustion efficiency is improved, exhaust gas is made clean, emission performance is improved, and noise is reduced by designing the air intake port having less air suction resistance and employing the swirl chamber. • Friction loss horsepower is reduced by reducing the weight of the main moving parts and setting the capacity of the auxiliary devices (water pump and oil pump) properly. • The weight, noise, and vibration are reduced by adjusting the clearance between each piston and cylinder properly. (3) Other items • Glow plugs which consume less electric power are employed for the starting aid to reduce the load on the battery. • Noise is reduced by improving the shape of the piston and applying float mounting of the head cover. • Reliability and durability are heightened by the developing technology based on experience and results of long development of construction machinery and engines for industrial use.

95 SERIES

01-3

GENERAL

GENERAL VIEW

GENERAL VIEW 4D95LWE-5

1. Crankshaft pulley 2. Fuel filter 3. Intake manifold

01-4

a The general views may differ depending on the product on which the engine is mounted.

4. Fuel injection pump 5. Starting motor

95 SERIES

GENERAL

6. Oil filter 7. Dipstick 8. Oil filler

95 SERIES

GENERAL VIEW

9. Alternator 10. Exhaust manifold 11. Thermostat

01-5

GENERAL

S4D95LWE-5

1. Crankshaft pulley 2. Fuel filter 3. Intake manifold

01-6

GENERAL VIEW

a The general views may differ depending on the product on which the engine is mounted.

4. Fuel injection pump 5. Starting motor

95 SERIES

GENERAL

6. Oil filter 7. Dipstick 8. Oil filler

95 SERIES

GENERAL VIEW

9. Alternator 10. Exhaust manifold 11. Thermostat

01-7

GENERAL

SPECIFICATIONS

SPECIFICATIONS Engine model

4D95LWE-5

Applicable machine

WA65-HH-6

S4D95LWE-5

WA70-HH-6

Number of cylinder – Bore × Stroke

(mm)

4 – 95 × 115

Total piston displacement

l {cc}

3.261 {3,261}

Performance

Dimensions

Firing order

WA80-HH-6

1–2–4–3

Overall length

(mm)

707

Overall width

(mm)

613

Overall height (excluding exhaust pipe)

(mm)

764

827

Flywheel horsepower

kW {HP}/rpm

40.5 {54.3}/2,350

44.8 {60.1}/2,350

50.0 {67.1}/2,270

Maximum torque

Nm {kgm}/rpm

190 {19.4}/1,600

210 {21.4}/1,600

240 {24.5}/1,600

High idle speed

(rpm)

2,650

2,520

Low idle speed

(rpm)

900

g/kWh {g/HPh}

262 {195}

253 {189}

257 {192}

(kg)

230

240

Fuel consumption ratio at rated point Dry weight Fuel pump

Bosch 4LC-35 type

Governor

Centrifugal, all speed type

Lubricating oil capacity (Refill capacity)

(l)

7.5 (7.0)

11.5 (11.0)

Coolant capacity

(l)

4.5

Alternator

12 V, 90 A

Starting motor

12 V, 2.2 kW

Turbocharger

—

TD04L

01-8

95 SERIES

GENERAL

GENERAL ASSEMBLY DRAWING

GENERAL ASSEMBLY DRAWING 4D95LWE-5 LEFT SIDE VIEW (WA65HH-6)

a. Crankshaft center b. Flywheel housing rear surface

01-10

95 SERIES

GENERAL

GENERAL ASSEMBLY DRAWING

4D95LWE-5 RIGHT SIDE VIEW (WA65HH-6)

a. Crankshaft center b. Flywheel housing rear surface

95 SERIES

01-11

GENERAL

GENERAL ASSEMBLY DRAWING

4D95LWE-5 FRONT VIEW (WA65HH-6)

a. Crankshaft center b. Cylinder center

01-12

95 SERIES

GENERAL

GENERAL ASSEMBLY DRAWING

4D95LWE-5 REAR VIEW (WA65HH-6)

a. Crankshaft center b. Cylinder center

95 SERIES

01-13

GENERAL

GENERAL ASSEMBLY DRAWING

S4D95LWE-5 LEFT SIDE VIEW (WA80HH-6)

a. Crankshaft center b. Flywheel housing rear surface

01-14

95 SERIES

GENERAL

GENERAL ASSEMBLY DRAWING

S4D95LWE-5 RIGHT SIDE VIEW (WA80HH-6)

a. Crankshaft center b. Flywheel housing rear surface

95 SERIES

01-15

GENERAL

GENERAL ASSEMBLY DRAWING

S4D95LWE-5 FRONT VIEW (WA80HH-6)

a. Crankshaft center b. Cylinder center

01-16

95 SERIES

GENERAL

GENERAL ASSEMBLY DRAWING

S4D95LWE-5 REAR VIEW (WA80HH-6)

a. Crankshaft center b. Cylinder center

95 SERIES

01-17

GENERAL

GENERAL ASSEMBLY DRAWING

a These dimensions are reference values for use when installing to a test bench.

DIMENSION TABLE

Dimensions for each part (mm) Engine

Machine model A

4D95LWE-5

WA65-HH-6 WA70-HH-6

707

344

764

532

S4D95LWE-5

WA80-HH-6

707

344

827

545

01-18

95 SERIES

GENERAL

ENGINE PERFORMANCE CURVE

ENGINE PERFORMANCE CURVE 4D95LWE-5 [Applicable machine: WA65-HH-6] Rated output: 40.5 kW {54.3 HP}/2,350 rpm (Gross) Max. torque: 190 Nm {19.4 kgm}/1,600 rpm (Gross)

95 SERIES

01-19

GENERAL

ENGINE PERFORMANCE CURVE

4D95LWE-5 [Applicable machine: WA70-HH-6] Rated output: 44.8 kW {60.1 HP}/2,350 rpm (Gross) Max. torque: 210 Nm {21.4 kgm}/1,600 rpm (Gross)

01-20

95 SERIES

GENERAL

ENGINE PERFORMANCE CURVE

4D95LWE-5 [Applicable machine: WA80-HH-6] Rated output: 50.0 kW {67.1 HP}/2,270 rpm (Gross) Max. torque: 240 Nm {24.5 kgm}/1,600 rpm (Gross)

95 SERIES

01-21

WEIGHT TABLE a The specifications may be different depending on the type of machine. Unit: kg

No.

Item

Components

4D95LWE-5

S4D95LWE-5

—

Turbocharger

Cylinder head assembly

Cylinder head, valve, valve spring

Cylinder block assembly

Cylinder block, main metal block, cylinder liner

Gear case (Front cover)

2.6

Oil pan

3.0

4.4

Flywheel assembly

Flywheel housing

4.9

Crankshaft assembly

Crankshaft, crankshaft gear

Camshaft assembly

Camshaft, camshaft gear, thrust plate

5.5

Piston and connecting rod assembly

Piston, piston ring, piston pin, connecting rod

Oil pump

0.5

Fuel injection pump

5.8

Water pump

8.1

Alternator

5.3

Starting motor

Flywheel, ring gear

STRUCTURE AND FUNCTION

11 STRUCTURE AND FUNCTION GENERAL STRUCTURE General structure .......................................................................................................................................... 11- 2 EXHAUST SYSTEM Turbocharger................................................................................................................................................. 11- 6 ENGINE BODY Cylinder head ................................................................................................................................................ 11- 8 Cylinder block ............................................................................................................................................... 11- 12 Main moving parts......................................................................................................................................... 11- 14 Timing gear ................................................................................................................................................... 11- 16 Valve system ................................................................................................................................................. 11- 18 Flywheel and flywheel housing ..................................................................................................................... 11- 20 LUBRICATION SYSTEM Lubrication system chart ............................................................................................................................... 11- 22 Oil pump........................................................................................................................................................ 11- 23 Oil filter .......................................................................................................................................................... 11- 24 FUEL SYSTEM Fuel system chart.......................................................................................................................................... 11- 25 Fuel injection pump ....................................................................................................................................... 11- 26 Fuel injection nozzle ..................................................................................................................................... 11- 28 COOLING SYSTEM Cooling system chart .................................................................................................................................... 11- 29 Thermostat and fan drive .............................................................................................................................. 11- 30 ELECTRICAL SYSTEM Starting and charging system electrical circuit diagram ................................................................................ 11- 33 Alternator ...................................................................................................................................................... 11- 34 Starting motor................................................................................................................................................ 11- 36 Engine starting device................................................................................................................................... 11- 37

95 SERIES

11-1

STRUCTURE AND FUNCTION

GENERAL STRUCTURE

GENERAL STRUCTURE a The shape is subject to machine models.

4D95LWE-5

1. Crankshaft pulley 2. Front oil seal 3. Crankshaft 4. Crankshaft gear 5. Connecting rod 6. Camshaft bushing 7. Camshaft gear 8. Front cover 9. Connecting rod bushing 10. Piston pin

11-2

11. Oil ring 12. Second ring 13. Top ring 14. Water pump 15. Piston 16. Fan pulley 17. Intake valve 18. Exhaust valve 19. Thermostat 20. Valve guide

21. Valve spring 22. Cylinder head cover 23. Rocker arm bracket 24. Rocker arm shaft 25. Cylinder head 26. Cylinder block 27. Push rod 28. Flywheel housing 29. Flywheel

95 SERIES

STRUCTURE AND FUNCTION

30. Ring gear 31. Tappet 32. Main bearing 33. Rear oil seal 34. Thrust bearing 35. Oil pan 36. Camshaft 37. Connecting rod cap 38. Oil filter 39. Dipstick

95 SERIES

GENERAL STRUCTURE

40. Oil cooler 41. Exhaust manifold 42. Filler cap 43. Rocker arm 44. Glow plug 45. Fuel injection nozzle 46. Hot plug 47. Intake manifold 48. Fuel injection pump 49. Starting motor 50. Oil strainer

Engine: 4D95LWE-5 Type: In-line, 4-cylinder, water cooled, precombustion chamber (swirl chamber) type, 4-cycle diesel engine

11-3

STRUCTURE AND FUNCTION

GENERAL STRUCTURE

S4D95LWE-5

1. Crankshaft pulley 2. Front oil seal 3. Crankshaft 4. Crankshaft gear 5. Connecting rod 6. Camshaft bushing 7. Camshaft gear 8. Front cover 9. Connecting rod bushing 10. Piston pin

11-4

11. Oil ring 12. Second ring 13. Top ring 14. Water pump 15. Piston 16. Fan pulley 17. Intake valve 18. Exhaust valve 19. Thermostat 20. Valve guide

21. Valve spring 22. Cylinder head cover 23. Rocker arm bracket 24. Rocker arm shaft 25. Cylinder head 26. Cylinder block 27. Push rod 28. Flywheel housing 29. Flywheel

95 SERIES

STRUCTURE AND FUNCTION

30. Ring gear 31. Tappet 32. Main bearing 33. Rear oil seal 34. Thrust bearing 35. Oil pan 36. Camshaft 37. Connecting rod cap 38. Oil filter 39. Dipstick

95 SERIES

GENERAL STRUCTURE

40. Oil cooler 41. Exhaust manifold 42. Filler cap 43. Rocker arm 44. Glow plug 45. Fuel injection nozzle 46. Hot plug 47. Intake manifold 48. Fuel injection pump 49. Starting motor 50. Oil strainer

Engine: S4D95LWE-5 Type: In-line, 4-cylinder, water cooled, precombustion chamber (swirl chamber) type, 4-cycle diesel engine

11-5

STRUCTURE AND FUNCTION

TURBOCHARGER

EXHAUST SYSTEM TURBOCHARGER TD04L

1. Blower housing 2. Screw rivet 3. Insert 4. Snap ring 5. O-ring 6. Snap ring 7. O-ring 8. Thrust bearing 9. Coupling assembly 10. Center housing 11. Back plate 12. Piston ring 13. Turbine housing 14. Turbine impeller 15. Bearing 16. Bearing

11-6

a The shape is subject to machine models.

17. Oil deflector 18. Thrust ring 19. Thrust sleeve 20. Piston ring 21. Blower impeller 22. Lock nut 23. Bolt, washer assembly 24. Actuator, waste gate valve

SPECIFICATIONS Type: TD04L Exhaust temperature: Max. 700ºC (inlet) Direction of rotation: Clockwise (as seen from blower) Actuator set pressure: 40 ± 4 kPa {300 ± 30 mmHg} (at 1 mm stroke)

A. Air intake inlet B. Compressed air outlet C. Exhaust inlet D. Exhaust outlet E. Oil inlet F. Oil outlet

95 SERIES

STRUCTURE AND FUNCTION

TURBOCHARGER

Outline of waste gate valve • This maintains a suitable supercharging pressure (set supercharging pressure) in order to prevent any excessive load on the engine by suppressing any supercharging above the necessary level from the compressor. In order to do this, waste gate valve (1) is installed in the exhaust circuit before the turbine. When supercharged pressure (A) near the compressor outlet port becomes high, if it exceeds the set pressure of the actuator (swing valve control (2)), waste gate valve (swing valve) (1) opens.

•

Point (c) where engine speed (a) and supercharging pressure (b) intersect is the point where the waste gate valves start to open.

•

Pressure (A) near the outlet port of the compressor passes through (B) and actuates actuator (2). Waste gate valve (1) opens, and part of the exhaust gas bypasses the turbine, so the output of the turbine drops and the set supercharging pressure is maintained.

95 SERIES

11-7

STRUCTURE AND FUNCTION

CYLINDER HEAD

ENGINE BODY CYLINDER HEAD 4D95LWE-5

1. Cylinder head 2. Cylinder head cover 3. Cylinder head mounting bolt 4. Filler cap 5. Valve guide 6. Glow plug lead

11-8

7. Valve seat insert 8. Blow-by suction pipe 9. Fuel injection nozzle 10. Glow plug 11. Nozzle holder 12. Hot plug

95 SERIES

STRUCTURE AND FUNCTION

SPECIFICATIONS Cylinder head • Precombustion chamber (swirl chamber) type • One-piece type • 2-valve for one cylinder • Injection nozzle mounted on cylinder head • With glow plug

95 SERIES

CYLINDER HEAD

Head cover • Float mount type

11-9

STRUCTURE AND FUNCTION

CYLINDER HEAD

S4D95LWE-5

1. Cylinder head 2. Cylinder head cover 3. Cylinder head mounting bolt 4. Filler cap 5. Valve guide 6. Glow plug lead

11-10

7. Valve seat insert 8. Fuel injection nozzle 9. Glow plug 10. Nozzle holder 11. Hot plug

95 SERIES

STRUCTURE AND FUNCTION

SPECIFICATIONS Cylinder head • Precombustion chamber (swirl chamber) type • One-piece type • 2-valve for one cylinder • Injection nozzle mounted on cylinder head • With glow plug

95 SERIES

CYLINDER HEAD

Head cover • Float mount type

11-11

STRUCTURE AND FUNCTION

CYLINDER BLOCK

CYLINDER BLOCK 4D95LWE-5 S4D95LWE-5

1. Main bearing cap 2. Main bearing cap bolt 3. Cylinder block 4. Camshaft bushing (No. 1 journal) 5. Camshaft bushing (No. 2 journal)

11-12

a The shape is subject to machine models.

6. Camshaft bushing (No. 3 journal) 7. Oil pump drive shaft bushing 8. Oil pump driven shaft a. Piston cooling nozzle

95 SERIES

STRUCTURE AND FUNCTION

CYLINDER BLOCK

CYLINDER BLOCK • Crankshaft: 5 bearings • Camshaft: 3 bearings CYLINDER • Linerless • Inside surface finishing: Honing

95 SERIES

11-13

STRUCTURE AND FUNCTION

MAIN MOVING PARTS

MAIN MOVING PARTS 4D95LWE-5 S4D95LWE-5

Crankshaft gear (No. of teeth: 24) 2. Crankshaft 3. Main bearing 4. Connecting rod bearing 5. Connecting rod 6. Cylinder block 7. Piston 8. Connecting rod bushing 9. Piston pin

11-14

10. Top ring 11. Second ring 12. Oil ring 13. Connecting rod cap 14. Main bearing cap 15. Main bearing cap bolt 16. Connecting rod cap bolt 17. Thrust bearing 18. Camshaft bushing

95 SERIES

STRUCTURE AND FUNCTION

Crankshaft • Closed die forging

MAIN MOVING PARTS

Piston ring

Piston • Swirl chamber type • Auto thermatic piston with steel strut ( S u p p r e s s e s h e a t e x pa n s i o n a n d k e e ps clearance from cylinder small) • Center of piston hole offset 1.0 mm (to reduce vibration) Top ring Second ring Oil ring (1) (2) (3) Half key Scraper type M-shape stone barrel barrel face. steel ring, 4D95LWE-5 face. Parkerizing. Hard chrome S4D95LWE-5 Hard chrome plating with plating. coil expander. Engine

95 SERIES

11-15

STRUCTURE AND FUNCTION

TIMING GEAR

TIMING GEAR WITHOUT FRONT PTO TYPE (HELICAL GEAR) a The numbers in ( ) are used when indicating other parts of the same type or when explaining the same part when seen from a different angle.

1. Oil pump drive gear (No. of teeth: 21) 2. Camshaft gear (No. of teeth: 48) 3. Crankshaft gear (No. of teeth: 24) 4. Idler gear (No. of teeth: 48) 5. Fuel Injection pump drive gear (No. of teeth: 48) 6. Thrust plate

11-16

7. Idler gear shaft 8. Idler gear bushing 9. Front seal A, B, C: Match marks for timing gears

95 SERIES

STRUCTURE AND FUNCTION

TIMING GEAR

SPECIFICATION Front oil seal • Single lip with dust seal

95 SERIES

11-17

STRUCTURE AND FUNCTION

VALVE SYSTEM

VALVE SYSTEM 4D95LWE-5 S4D95LWE-5

1. Valve cotter 2. Valve seal 3. Valve spring 4. Intake valve 5. Exhaust valve 6. Push rod 7. Tappet 8. Camshaft 9. Thrust plate

11-18

10. Cam gear (No. of teeth: 48) 11. Spring seat 12. Rocker arm spring 13. Rocker arm bracket 14. Rocker arm shaft 15. Adjustment screw 16. Locknut 17. Rocker arm

95 SERIES

STRUCTURE AND FUNCTION

VALVE SYSTEM

Valve lift • Intake valve: 9.6 mm • Exhaust valve: 10.6 mm

95 SERIES

11-19

STRUCTURE AND FUNCTION

FLYWHEEL AND FLYWHEEL HOUSING

FLYWHEEL AND FLYWHEEL HOUSING WITHOUT REAR PTO TYPE

a There may be differences according to the machine model. a The numbers in ( ) are used when indicating other parts of the same type or when explaining the same part when seen from a different angle.

1. Starting motor 2. Flywheel housing 3. Crankshaft 4. Rear oil seal (Dry type: Single lip) 5. Flywheel 6. Ring gear (No. of teeth: 110)

11-20

95 SERIES

STRUCTURE AND FUNCTION

95 SERIES

FLYWHEEL AND FLYWHEEL HOUSING

11-21

STRUCTURE AND FUNCTION

LUBRICATION SYSTEM CHART

LUBRICATION SYSTEM LUBRICATION SYSTEM CHART

1. Oil strainer 2. Oil pump 3. Oil cooler 4. Regulator valve 5. Oil filter 6. Safety valve 7. Crankshaft 8. Camshaft 9. Piston 10. Intake and exhaust valve

11-22

11. Rocker arm 12. Timing gear W. Cooling water

95 SERIES

STRUCTURE AND FUNCTION

OIL PUMP

1. Bushing 2. Drive gear (No. of teeth: 7) 3. Pump cover 4. Oil pump drive gear (No. of teeth: 21) 5. Drive shaft 6. Driven shaft 7. Driven gear (No. of teeth: 7) 8. Regulator valve 9. Valve spring

95 SERIES

Specifications Oil pump • Type: Gear pump • Pump speed: Engine speed × 1.143 Regulator valve • Set pressure: 588 ± 49 kPa {6.0 ± 0.5 kg/cm2}

11-23

STRUCTURE AND FUNCTION

OIL FILTER

1. Relief valve 2. Cartridge

Relief valve • Cracking pressure: 100 ± 20 kPa {1 ± 0.2 kg/cm2}

A. Oil inlet B. Oil outlet

11-24

95 SERIES

STRUCTURE AND FUNCTION

FUEL SYSTEM CHART

FUEL SYSTEM FUEL SYSTEM CHART

A. Fuel inlet B. Fuel outlet 1. Fuel tank 2. Priming pump 3. Fuel filter (including gauze filter) 4. Overflow valve 5. Fuel injection pump (including feed pump) 6. Fuel injection nozzle

95 SERIES

11-25

STRUCTURE AND FUNCTION

FUEL INJECTION PUMP

FUEL INJECTION PUMP 4D95LWE-5 S4D95LWE-5

1. Governor 2. Fuel injection pump drive gear (No. of teeth 48) 3. Drive shaft 4. Pump holder 5. Fuel filter

11-26

6. Fuel injection pipe (No. 1) 7. Fuel injection pipe (No. 2) 8. Fuel injection pipe (No. 3) 9. Fuel injection pipe (No. 4) 10. Fuel injection nozzle

95 SERIES

STRUCTURE AND FUNCTION

A. Fuel inlet (From fuel tank fuel filter) B. From fuel filter to fuel injection pump C. From fuel injection pump to fuel injection nozzle D. To fuel tank

FUEL INJECTION PUMP

SPECIFICATIONS Fuel injection pump • Type: Bosch type VE • Lubrication method: Lubrication with fuel Governor • Type: Bosch all-speed type

95 SERIES

11-27

STRUCTURE AND FUNCTION

FUEL INJECTION NOZZLE

FUEL INJECTION NOZZLE For direct fuel injection type For swirl chamber type 4D95LWE-5 S4D95LWE-5

1. Nozzle holder 2. Adjustment shim 3. Nozzle spring 4. Spring seat 5. Retaining cap 6. Nozzle body 7. Needle valve

Fuel injection nozzle • Type: Bosch throttle nozzle type • Injection pressure (opening pressure): 11.8 MPa {120 kg/cm2} • Opening pressure adjustment: Shim adjustment

A. Fuel inlet port (from injection pump) B. Fuel spray (inside swirl chamber) C. Fuel return port (to fuel tank)

11-28

95 SERIES

STRUCTURE AND FUNCTION

COOLING SYSTEM CHART

COOLING STSTEM COOLING SYSTEM CHART 4D95LWE-5 S4D95LWE-5

1. Radiator 2. Thermostat 3. Water temperature sensor 4. Water pump 5. Water manifold 6. Cylinder head 7. Piston 8. Cylinder block

95 SERIES

11-29

STRUCTURE AND FUNCTION

THERMOSTAT AND FAN DRIVE

THERMOSTAT AND FAN DRIVE a The shape is subject to machine models.

1. Fan belt 2. Water pump 3. Fan pulley 4. Crankshaft pulley 5. Crankshaft 6. Thermostat case cover 7. Thermostat 8. Thermostat case 9. Alternator

11-30

A. Water outlet (to radiator) B. Water inlet (from radiator) a, b, c: Outside diameter of pulley d. Heater pickup port e. Thermo sensor (installed on some models) f. Water temperature gauge pickup port

95 SERIES

STRUCTURE AND FUNCTION

THERMOSTAT AND FAN DRIVE

Outer diameter of pulley (mm) Engine

Applicable machine a

4D95LWE-5

WA65-HH-6, WA70-HH-6

138

76.1

170

S4D95LWE-5

WA80-HH-6

138

76.1

170

95 SERIES

11-31

STRUCTURE AND FUNCTION

THERMOSTAT AND FAN DRIVE

THERMOSTAT (WITHOUT JIGGLE VALVE)

1. Piston 2. Case 3. Pellet 4. Seat 5. Valve 6. Case 7. Spring 8. Bypass spring 9. Bypass valve 10. Bypass seat 11. E-ring

11-32

95 SERIES

STRUCTURE AND FUNCTION

STARTING AND CHARGING SYSTEM ELECTRICAL CIRCUIT DIAGRAM

ELECTRICAL SYSTEM STARTING AND CHARGING SYSTEM ELECTRICAL CIRCUIT DIAGRAM 4D95LWE-5 S4D95LWE-5

1. Water temperature sensor 2. Oil pressure switch 3. Water temperature gauge 4. Oil pressure gauge 5. Glow lamp 6. Machine monitor 7. Glow plug 8. Glow heater relay 9. Fuse

95 SERIES

10. Starting switch 11. Safety relay 12. Charge lamp 13. Starting motor 14. Alternator 15. Battery relay 16. Battery 17. Machine controller 18. Surge-killer

11-33

STRUCTURE AND FUNCTION

ALTERNATOR

ALTERNATOR ALTERNATOR WITH BUILT-IN REGULATOR (Open type, 90A) a The shape is subject to machine models.

1. Alternator (body) 2. Alternator pulley 3. Terminal B 4. Internal connection diagram 4A. Alternator assembly 4B. IC regulator 4C. Terminal L load 4D. Starting switch 4E. Battery

11-34

95 SERIES

STRUCTURE AND FUNCTION

ALTERNATOR

Pulley Engine

Machine model

4D95LWE-5

WA65-HH-6 WA70-HH-6

S4D95LWE-5

WA80-HH-6

95 SERIES

Specifications

Number of stage

Outside diameter (mm)

Weight (kg)

Open-type

12 V, 90 A

76.1

4.7

Open-type

12 V, 90 A

76.1

4.7

Type

11-35

STRUCTURE AND FUNCTION

STARTING MOTOR

STARTING MOTOR a The shape is subject to machine models.

For 2.2 kW

1. Pinion gear 2. Magnetic switch 3. Starting motor assembly 4. Jump start prevention cover 5. 50 (terminal C) 6. 30 (terminal B)

Engine

Machine model

4D95LWE-5

WA65-HH-6 WA70-HH-6

S4D95LWE-5

WA80-HH-6

11-36

7. Internal connection diagram 7A. Relay 7B. Starting switch 7C. Battery 7D. 30 (terminal B) 7E. 50 (terminal C)

Specifications

Number of pinion teeth

Weight (kg)

Non-oil proof type manufactured by DENSO

12 V, 2.2 kW

6.0

Non-oil proof type manufactured by DENSO

12 V, 2.2 kW

6.0

Type

95 SERIES

STRUCTURE AND FUNCTION

ENGINE STARTING DEVICE

ENGINE STARTING DEVICE GLOW PLUG (METAL 2-WIRE TYPE GLOW PLUG)

1. Heat generation coil (Fe-Cr) 2. Control coil (Fe) 3. Body 4. Rated voltage color marking place

95 SERIES

SPECIFICATION • Rated voltage (color marking): 12 V (Blue) • Type: Quick type • Name: Metal 2-wire type glow plug

11-37

STRUCTURE AND FUNCTION

ENGINE STARTING DEVICE

GLOW CONTROLLER 1. 2. 3. 4. 5.

Connector (round 8-pin), (Short 8-pin) Lead wire Case Bracket Label Pin No. 1 2 3 4 5 6

Color of lead wire Green/red White/red Blue/white White Black/white Red/yellow

a The shapes of the controllers for 12V and 24V are the same but the colors of labels (5) are different. Red: 12 V Black: 24 V WATER TEMPERATURE SENSOR 1. Water temperature sensor

GLOW RELAY (QUICK GLOW SYSTEM) 1. Glow relay 2. Lead wire 3. Connector (round 2-in)

11-38

95 SERIES

12 TESTING AND ADJUSTING PERFORMANCE TEST Run-in standard ............................................................................................................................................ 12Performance test criteria .............................................................................................................................. 12Testing and adjusting data............................................................................................................................ 12Testing and adjusting tools list...................................................................................................................... 12-

2 4 6 7

INTAKE AND EXHAUST SYSTEM Adjusting valve clearance............................................................................................................................. 12- 8 ENGIN BODY Measuring compression pressure ................................................................................................................ 12- 10 FUEL SYSTEM Adjusting fuel injection pressure (Cracking pressure) .................................................................................. 12- 11 Shim data for adjusting injection pressure.................................................................................................... 12- 12 Testing and adjusting fuel injection timing .................................................................................................... 12- 13 Table of injection pumps using plunger with stepped lead ........................................................................... 12- 18 Adjusting fuel injection rate........................................................................................................................... 12- 19 Governor adjustment standard ..................................................................................................................... 12- 20 TROUBLESHOOTING Governor adjustment standard ..................................................................................................................... 12- 24 Points on troubleshooting ............................................................................................................................. 12- 28

95 SERIES

12-1

TESTING AND ADJUSTING

PERFORMANCE TEST

PERFORMANCE TEST a Load are given for the case of the dynamometer arm length is 716 mm. The list shows the standard on condition that the fan is removed.

RUN-IN STANDARD

Engine model

Order

Applicable machine

Item 1

Running time

min.

Engine speed

rpm

900

1,200

1,400

1,600

2,350

Load

N {kg}

0 {0}

1 {10}

1.5 {15}

2.5 {25}

2.3 {23}

Output

kW {HP}

0 {0}

8.8 {12}

15.4 {21}

29.4 {39}

40.5 {54}

Running time

min.

Engine speed

rpm

900

1,200

1,400

1,600

2,350

Load

N {kg}

0 {0}

1 {10}

1.5 {15}

2.5 {25}

Output

kW {HP}

0 {0}

8.8 {12}

15.4 {21}

29.4 {39}

44.8 {60}

Running time

min.

Engine speed

rpm

900

1,200

1,400

1,600

2,270

Load

N {kg}

0 {0}

1 {10}

1.5 {15}

2.5 {25}

3 {30}

Output

kW {HP}

0 {0}

8.8 {12}

15.4 {21}

29.4 {39}

50.0 {67}

WA65-HH-6

4D95LWE-5

WA70-HH-6

S4D95LWE-5 WA80-HH-6

12-2

95 SERIES

TESTING AND ADJUSTING

PERFORMANCE TEST

PERFORMANCE TEST CRITERIA

Engine model

Applicable machine

Test item

Specified value (fully equipped)

Engine speed (rpm)

Dynamometer (kg)

Flywheel horsepower

40.5 kW {54.3 HP}/2,350 rpm

2,350 ± 50

22.2 – 24.6

Maximum torque

190 Nm {19.4 kgm}/1,600 rpm

1,600 ± 50

25.7 – 28.5

High idle speed

2,650 rpm

2,650 ± 50

—

Low idle speed

900 rpm

900 ± 50

—

Flywheel horsepower

44.8 kW {60.1 HP}/2,350 rpm

2,350 ± 50

24.6 – 27.3

Maximum torque

210 Nm {21.4 kgm}/1,600 rpm

1,600 ± 50

28.3 – 31.4

High idle speed

2,650 rpm

2,650 ± 50

—

Low idle speed

900 rpm

900 ± 50

—

Flywheel horsepower

50.0 kW {67.1 HP}/2,270 rpm

2,270 ± 50

28.5 – 31.5

Maximum torque

240 Nm {24.5 kgm}/1,600 rpm

1,600 ± 50

32.5 – 35.9

High idle speed

2,520 rpm

2,520 ± 50

—

Low idle speed

900 rpm

900 ± 50

—

WA65-HH-6

4D95LWE-5

WA70-HH-6

S4D95LWE-5 WA80-HH-6

12-4

95 SERIES

TESTING AND ADJUSTING

PERFORMANCE TEST

a Fuel used: ASTM D975 No. 1 or No. 2 diesel fuel. a Lubrication oil used: CLASS-CD SAE30.

Output (kW{HP})

Torque (Nm{kgm})

38.4 – 42.5 kW {51.5 – 57.0 HP}

180 – 200 Nm {18.4 – 20.4 kgm}

42.6 – 47.2 kW {57.1 – 63.3 HP}

47.5 – 52.5 kW {63.7 – 70.4 HP}

95 SERIES

199 – 221 Nm {20.3 – 22.5 kgm}

228 – 252 Nm {23.3 – 25.7 kgm}

Exhaust temperature (ºC) (t=Intake temp. –25ºC)

Fuel consumption at rated point (g/kWh {g/HPh})

Coolant temperature (ºC)

Lubrication oil temperature (ºC)

Lubrication oil pressure (kPa{kg/cm2})

262 {195}

70 – 90

90 – 120

343 – 588 {3.5 – 6.0}

70 – 90

90 – 120

Max. 670

70 – 90

90 – 120

—

70 – 90

Min. 80

Min. 98 {Min. 1.0}

—

70 – 90

90 – 120

343 – 588 {3.5 – 6.0}

Max. 620

70 – 90

90 – 120

Max. 670

70 – 90

90 – 120

—

70 – 90

Min. 80

Min. 98 {Min. 1.0}

—

70 – 90

90 – 120

343 – 588 {3.5 – 6.0}

Max. 640

70 – 90

90 – 120

Max. 670

70 – 90

90 – 120

—

70 – 90

Min. 80

253 {189}

257 {192}

Min. 98 {Min. 1.0}

Max. 620

—

12-5

TESTING AND ADJUSTING

PERFORMANCE TEST

TESTING AND ADJUSTING DATA

Cooling system

Fuel system

Lubrication system

Engine body

Intake and exhaust system

Performance

Classification

Engine model

4D95LWE-5

S4D95LWE-5

Applicable machine model

WA65-HH-6 WA70-HH-6

WA80-HH-6

Unit

Standard value

Permissible value

Standard value

Permissible value

High idle speed

rpm

2,650 ± 50

2,520 ± 50

Low idle speed

rpm

900 ± 50

0ºC (without starting aid)

rpm

Min. 150

—

Min. 150

—

–20ºC (with starting aid)

rpm

Min. 100

—

Min. 100

—

Item

Condition, etc.

Engine speed

Necessary starting speed Intake resistance

At all speed

mmH2O

Max. 310

762

Max. 310

762

Intake pressure

At rated output

mmHg

—

Min. 280

Max. 200

Exhaust pressure (Turbine inlet press.)

At rated output

mmHg

—

Min. 280

Max. 200

Exhaust temperature (Turbine inlet temp.)

All speed (20ºC)

ºC

Max. 670

700

Max. 670

700

Max. 4.0

6.0

Max. 4.0

6.0

Max. 1.5

2.5

Max. 1.5

2.5

—

Quick acceleration (Low idle high idle) Exhaust gas color

At rated output

Bosch index

At high idle Valve clearance (When engine is hot or cold)

Intake valve

0.35

—

0.35

—

Exhaust valve

0.50

—

0.50

—

Compression pressure (SAE30)

Oil temperature: 40 – 60ºC (Engine speed: 320 – 360 rpm)

MPa {kg/cm2}

Min. 2.9 {Min. 30}

2.1 {20}

Min. 2.9 {Min. 30}

2.1 {20}

Blow-by pressure (SAE30)

At rated output Water temperature: Min. 70ºC

mmH2O

Max. 100

200

Max. 100

200

At rated output (SAE 30)

MPa {kg/cm2}

0.34 – 0.59 {3.5 – 6.0}

0.21 {2.1}

(3.0 – 6.0)

0.21 {2.1}

At rated output (SAE 10W)

MPa {kg/cm2}

0.34 – 0.54 {3.5 – 5.5}

0.21 {2.1}

(3.0 – 5.5)

0.21 {2.1}

At low idle (SAE 30)

MPa {kg/cm2}

Min. 0.1 {Min. 1.0}

0.07 {0.7}

Min. 0.1 {Min. 1.0}

0.07 {0.7}

At low idle (SAE 10W)

MPa {kg/cm2}

Min. 0.08 {Min. 0.8}

0.07 {0.7}

Min. 0.08 {Min. 0.8}

0.07 {0.7}

Oil temperature

All speed (oil in oil pan)

ºC

80 – 120

125

80 – 120

120

Oil consumption ratio

At continuous rated output (Ratio to fuel consumption)

Max. 0.5

1.0

Max. 0.5

1.0

Fuel injection pressure

Nozzle tester

MPa {kg/cm2}

11.8 +1.3 +0.5

10.1 {103}

11.8 +1.3 +0.5

{120 +13 +5 }

10.1 {103}

Fuel injection timing

B.T.D.C.

degree

After 5.3 ± 0.75 (A.T.D.C)

After 7.8 ± 0.75 (A.T.D.C)

Radiator pressure valve

Opening pressure (Differential pressure)

MPa {kg/cm2}

—

Fan speed

At rated engine speed

rpm

—

Fan belt tension (Alternator to fan pulley)

Deflects when pushed with a force of 6 kg

Oil pressure (Oil temperature: Min. 80ºC)

6 – 10

a The values given in the Testing and Adjusting Data are NOT for adjustment of the output. Do not use these values as a guide to change the setting of the fuel injection pump.

12-6

95 SERIES

TESTING AND ADJUSTING

PERFORMANCE TEST

TESTING AND ADJUSTING TOOLS LIST Testing and adjusting item

Symbol

Adjusting valve clearance Testing compression

Adjusting fuel injection pressure

95 SERIES

Part No.

Part name

Q’ty

795-114-1370

Feeler gauge

795-502-1205

Compression gauge

• 795-502-1380

Adapter

795-102-2102

Spring pusher

Commercial item

Dial gauge

–

Commercial item

Gauge stand

Commercial item

Dial gauge

Remarks 0.35, 0.50 mm 0 – 70 kg/cm2

BOSCH tool No. RB No.: 9 681 610 171

12-7

TESTING AND ADJUSTING

INTAKE AND EXHAUST SYSTEM

INTAKE AND EXHAUST SYSTEM ADJUSTING VALVE CLEARANCE 1. Remove cylinder head cover. 2. Rotate the crankshaft in the normal direction. While watching the movement of the intake valve of No. 4 cylinder, bring the No. 1 cylinder into Compression Top Dead Center position and align the TOP engraved mark on crankshaft pulley (1) with pointer (2). a TOP engraved mark to be aligned with pointer: 1.4 TOP mark a When the No. 1 cylinder comes near Compression Top Dead Center position, No. 4 intake valve will start to move (open). 3. Adjust the valve clearance for valves marked q in the valve arrangement chart.

4D95LWE-5 S4D95LWE-5

4. Rotate the crankshaft in the normal direction by one revolution and adjust the valve clearance for the remaining valves marked Q. a Valve clearance (Engine at hot or cold)

12-8

Intake valve

Exhaust valve

0.35 mm

0.50 mm

95 SERIES

TESTING AND ADJUSTING

INTAKE AND EXHAUST SYSTEM

a To adjust the valve clearance, loosen lock nut (3) on adjustment screw (4), insert feeler gauge A corresponding to the specified clearance between valve stem (5) and rocker arm (6), and adjust the clearance with the adjustment screw until the thickness gauge can slide lightly.

5. After the clearance is properly adjusted, tighten the lock nut to secure the adjustment screw. 3 Lock nut: 45 ± 5 Nm {4.5 ± 0.5 kgm}

a Intake and exhaust valve clearances may be adjusted for each cylinder in a firing order by rotating the crankshaft with following angle at a time in the normal direction. a Crankshaft rotating angle: 180º a Engine firing order: 1 – 2 – 4 – 3

95 SERIES

12-9

TESTING AND ADJUSTING

ENGINE BODY

ENGINE BODY MEASURING COMPRESSION PRESSURE Measurement procedure k While measuring the compression pressure,

tak e c a re not t o b ur n yo ur se l f o n t he exhaust manifold or muffler, and be careful not to get caught in any revolving part of the engine. a Measure the compression pressure while the engine is warm. (Oil temperature: 40 – 60ºC) 1. Adjust the valve clearance properly. For details, see ADJUSTING VALVE CLEARANCE. 2. Remove spill tube and disconnect fuel injection pipe. 3. Remove the wiring of the fuel cut solenoid into which fuel injection pump is built. 4. Remove nozzle holder assembly for each cylinder. a Remove the nozzle holder assembly by prying it with the spill tube mounting bolt. a Take care not to let any dirt or foreign matter get into the cylinder. 5. Install adapter to the nozzle holder mounting section of the cylinder to be measured, and tighten the adapter to the specified torque. 3 Torque: 45 ± 5 Nm {4.5 ± 0.5 kgm} 6. Connect compression gauge B1 to adapter. 7. Place the fuel control lever in NO INJECTION position, crank the engine with the starting motor, and read the gauge when the pointer is stabilized. k If you do not put the fuel control lever in

NO INJECTION position, fuel will blow out. a Most compression leakage can be prevented by applying a small amount of oil to the mounting section of the adapter. a For the reference values of the compression pressure, see TESTING AND ADJUSTING DATA.

12-10

95 SERIES

TESTING AND ADJUSTING

FUEL SYSTEM

FUEL SYSTEM ADJUSTING FUEL INJECTION PRESSURE (CRACKING PRESSURE) 1. Remove retaining cap (1). 2. Remove nozzle (2), spring seat (3), and nozzle spring (4).

For swirl chamber type 4D95LWE-5 S4D95LWE-5

3. Adjust thickness of shim (5) to adjust injection pressure (cracking pressure). a Pressure adjustment for 0.1 mm of shim thickness: Approx. 0.93 MPa {9.5 kg/cm2} 3 Retaining cap: 73 ± 5 Nm {7.5 ± 0.5 kgm}

95 SERIES

12-11

TESTING AND ADJUSTING

FUEL SYSTEM

SHIM DATA FOR ADJUSTING INJECTION PRESSURE

Engine model

4D95LWE-5 S4D95LWE-5

Shim contour a = 4.5 mm b = 11.5 mm

Shim thickness (Range)

Shim thickness (Interval)

0.50 – 1.54 mm

0.02 mm

Part No.

Thickness (mm)

Part No.

Thickness (mm)

DK150523-5000

0.50

DK150523-7900

1.08

DK150523-5100

0.52

DK150523-8000

1.10

DK150523-5200

0.54

DK150523-8100

1.12

DK150523-5300

0.56

DK150523-8200

1.14

DK150523-5400

0.58

DK150523-8300

1.16

DK150523-5500

0.60

DK150523-8400

1.18

DK150523-5600

0.62

DK150523-8500

1.20

DK150523-5700

0.64

DK150523-8600

1.22

DK150523-5800

0.66

DK150523-8700

1.24

DK150523-5900

0.68

DK150523-8800

1.26

DK150523-6000

0.70

DK150523-8900

1.28

DK150523-6100

0.72

DK150523-9000

1.30

DK150523-6200

0.74

DK150523-9100

1.32

DK150523-6300

0.76

DK150523-9200

1.34

DK150523-6400

0.78

DK150523-9300

1.36

DK150523-6500

0.80

DK150523-9400

1.38

DK150523-6600

0.82

DK150523-9500

1.40

DK150523-6700

0.84

DK150523-9600

1.42

DK150523-6800

0.86

DK150523-9700

1.44

DK150523-6900

0.88

DK150523-9800

1.46

DK150523-7000

0.90

DK150523-9900

1.48

DK150523-7100

0.92

DK150530-0000

1.50

DK150523-7200

0.94

DK150530-0100

1.52

DK150523-7300

0.96

DK150530-0200

1.54

DK150523-7400

0.98

DK150523-7500

1.00

DK150523-7600

1.02

DK150523-7700

1.04

DK150523-7800

1.06

12-12

95 SERIES

TESTING AND ADJUSTING

FUEL SYSTEM

TESTING AND ADJUSTING FUEL INJECTION TIMING a Teat and adjust the fuel injection timing by the following static injection timing adjustment method. Do not recommend another method (the match mark method, delivery valve method, etc.) 1. Cancel the CSD (Cold Start Device) according to the following procedure. Reference: If the engine is warmed up, the CSD rod extends because of the hot coolant and pushes the lever to cancel the CSD. Since the machine needs to be in this state for testing and adjusting the fuel injection timing, the following work is required. 1) Remove coolant hose (1). k If you disconnect the coolant hose while the coolant temperature is high, you may be scalded with the hot coolant. Accordingly, ensure that the coolant temperature is low before disconnecting the coolant hose. 6

Coolant: Approx. 4.5 l

2) Insert a screwdriver etc. in lever guide hole (2) of the WAX-CSD and rotate the lever counterclockwise. a Do not rotate the lever clockwise. 3) Insert spacer (3) at least 12 mm thick in the clearance between the WAX-CSD rod and lever. a You may use a nut etc. 12 mm in width across flats as the spacer. 2. Remove cylinder head cover (4).

3. Set the No. 1 cylinder to the compression top dead center. 1) Rotate the crankshaft forward and set fuel injection timing stamp line (5) of the crankshaft pulley to pointer (6). 2) Move the air intake valve and exhaust valve of the No. 1 cylinder with the hand to ensure that there is a valve clearance. a If the cylinder is not in this state, rotate the crankshaft one more turn.

95 SERIES

12-13

TESTING AND ADJUSTING

FUEL SYSTEM

4. Remove snap ring (7) at the end of the rocker shaft and remove air intake rocker arm (8) of the No. 1 cylinder.

5. Using spring pusher C1, compress the valve spring and remove valve cotter (9). 6. Loosen spring pusher C1 and remove spring seat (10) and valve spring (11). a If the crankshaft is rotated too much in the following work, the valve may fall in the cylinder. Take care.

7. With air intake valve (12) in contact with piston top (13), rotate the valve stem so that it will contact the piston securely.

8. Apply dial gauge C2 to the valve stem end and rotate the crankshaft forward and in reverse. Set the dial gauge to 0 at a point where the pointer starts turning in reverse a While eliminating the play of the dial gauge and gauge stand, apply the dial gauge straight to the valve stem end.

12-14

95 SERIES

TESTING AND ADJUSTING

FUEL SYSTEM

9. Remove distributor head bolt (14) and gasket from the injection pump.

10. Set dial gauge C3 to the injection pump and rotate the crankshaft in reverse. Set C3 to 0 at a point where the pointer stops moving (at the feed bottom dead center of the pump plunger) 11. While watching C2 and C3 alternately, rotate the crankshaft forward and check that C2 (on the valve side) reads the following value when C3 (on the injection pump side) reads 1.5 mm of the plunger lift. Machine model

Standard value of C2 (on valve side) (when C3 is 1.5 mm)

WA65-HH-6

0.33 ± 0.09 mm

WA70-HH-6

0.33 ± 0.09 mm

WA80-HH-6

0.71 ± 0.09 mm

a Just before measuring with C3, be sure to check with gauge C2 that the piston has lowered (it is on the A.T.D.C side). a Carry out this measurement at least 3 times and check that the results are the same. If the results are dispersed, find out the cause by checking the dial gauge, gauge stand, etc. and then repeat the work from step 8.

95 SERIES

12-15

TESTING AND ADJUSTING

FUEL SYSTEM

12. Adjusting injection timing a As a result of testing, if the fuel injection timing is out of the standard value, adjust it according to the following procedure. 1) Remove injection pipe (15). 2) Remove support bracket (17) from the pump bottom. 3) Loosen injection pump mounting nuts (16). 4) Change the inclination of the fuel injection pump. a If the injection pump is inclined engine outside, the injection timing is lagged. If the former is inclined cylinder block side, the latter is advanced. 5) Tighten pump mounting nuts (16) and check the injection timing according to step 11. 6) After ensuring that the injection timing is normal, tighten pump mounting nuts (16) and install support bracket (17) to the pump bottom. 7) Install injection pipe (15). 3 Sleeve nut: 19.6 – 24.5 Nm {2 – 2.5 kgm} 13. Remove dial gauges C2 and C3. 14. Install distributor head bolt (14) to the fuel injection pump. a Set the gasket to the bolt securely. 3 Distributor head bolt (14): 13.8 – 19.6 Nm {1.4 – 2.0 kgm}

15. Install the following part in the reverse order of removing. • Valve spring (11) • Spring seat (10) • Valve cotter (9) • Air intake rocker arm (8) of the No. 1 cylinder and snap ring (7) • Cylinder head cover (4)

12-16

95 SERIES

TESTING AND ADJUSTING

FUEL SYSTEM

16. Remove spacer (3) 12 mm thick set to the CSD rod and install coolant hose (1).

17. Add coolant. 6

Coolant: Approx. 4.5 l

95 SERIES

12-17

TESTING AND ADJUSTING

FUEL SYSTEM

TABLE OF INJECTION PUMPS USING PLUNGER WITH STEPPED LEAD Engine

Machine model

Injection pump part No.

4D95LWE-5

WA65-HH-6 WA70-HH-6

6272-71-1140 6272-71-1130

S4D95LWE-5

WA80-HH-6

6273-71-1130

12-18

95 SERIES

TESTING AND ADJUSTING

FUEL SYSTEM

ADJUSTING FUEL INJECTION RATE Fuel injection pump Engine

4D95LWE-5 S4D95LWE-5

Item Manufacturer

Bosch

Model

Bosch PES-A

Rotation direction

Clockwise seen from drive side

Injection order

1–2–4–3

Pre-stroke

1.5 ± 0.05 mm

Service adjustment standard condition (Bench test) Engine

4D95LWE-5 S4D95LWE-5

Item Nozzle holder

Manufacturer part No.

105780-2080

Injection nozzle

Manufacturer part No.

105780-0000

kg/cm2

175

Inside diameter x Outside diameter x Length (mm)

2 × 6 × 600

aInjection pressure Injection pipe

Feed pressure

kg/cm

1.6

Actual machine adjustment standard condition Engine

4D95LWE-5 S4D95LWE-5

Item Nozzle holder

Manufacturer part No.

6202-12-3110

Injection nozzle

Manufacturer part No.

6202-12-3130

kg/cm2

120

Inside diameter x Outside diameter x Length (mm)

2 × 6 × 600

aInjection pressure Injection pipe

Feed pressure

kg/cm

1.6

a The injection pressure (valve cracking pressure) shown in the above table is the pressure set during the injection pump test, which is different from the injection pressure of the injection pump mounted on the engine. Fuel injection standard Engine

Applicable machine

WA65-HH-6

Injection pump part No.

6272-71-1130

4D95LWE-5 WA70-HH-6

S4D95LWE-5

95 SERIES

WA80-HH-6

6272-71-1140

6273-71-1130

Pump speed (rpm)

Injection quantity

450

49.2 ± 4.5

800

56.0 ± 4

900

54.4 ± 1.5

1175

48.4 ± 4

450

55.4 ± 4.5

800

59.7 ± 4

900

58.4 ± 1.5

1175

51.9 ± 4

500

56.4 ± 4.5

800

66.9 ± 4

900

65.6 ± 1.5

1135

59.0 ± 4

Unevenness

Max. 5.0

Max. 5.5

12-19

TESTING AND ADJUSTING

FUEL SYSTEM

GOVERNOR ADJUSTMENT STANDARD WA65-HH-6 Pump speed 100 450 800 900 1175 1325 450

Injection quantity (mm3/st) 80 49.2 56 54.4 48.4 10.5 8.9

WA70-HH-6 Pump speed 100 450 800 900 1175 1325 450

12-20

Injection quantity (mm3/st) 80 55.4 59.7 58.4 51.9 8.8 8.9

95 SERIES

TESTING AND ADJUSTING

FUEL SYSTEM

WA80-HH-6 Pump speed 100 500 800 900 1135 1260 450

95 SERIES

Injection quantity (mm3/st) 80 56.4 66.9 65.6 59 12.1 8.9

12-21

TROUBLESHOOTING

TROUBLESHOOTING Method of using troubleshooting charts ........................................................................................................12- 24 Points on troubleshooting..............................................................................................................................12- 28 S-1 Starting performance is poor (Starting always takes time) .....................................................................12- 29 S-2 Engine does not start..............................................................................................................................12- 30 1) Engine does not turn ..........................................................................................................................12- 30 2) Engine turns but no exhaust gas comes out (Fuel is not being injected)...........................................12- 31 3) Exhaust gas comes out but engine does not start (Fuel is being injected) ........................................12- 32 S-3 Engine does not pick up smoothly (Follow-up is poor) ...........................................................................12- 33 S-4 Engine stops during operations ..............................................................................................................12- 34 S-5 Engine does not rotate smoothly ............................................................................................................12- 35 S-6 Engine lacks output (no power) ..............................................................................................................12- 36 S-7 Exhaust gas is black (incomplete combustion) ......................................................................................12- 37 S-8 Oil consumption is excessive (or exhaust gas is blue) ...........................................................................12- 38 S-9 Oil becomes contaminated quickly .........................................................................................................12- 39 S-10 Fuel consumption is excessive.............................................................................................................12- 40 S-11 Oil is in coolant, or coolant spurts back, or coolant level goes down....................................................12- 41 S-12 Oil pressure lamp lights up (drop in oil pressure) .................................................................................12- 42 S-13 Oil level rises ........................................................................................................................................12- 43 S-14 Coolant temperature becomes too high (overheating) .........................................................................12- 44 S-15 Abnormal noise is made.......................................................................................................................12- 45 S-16 Vibration is excessive ...........................................................................................................................12- 46

95 SERIES

12-23

TROUBLESHOOTING

METHOD OF USING TROUBLESHOOTING CHARTS

METHOD OF USING TROUBLESHOOTING CHARTS The troubleshooting chart consists of the “questions”, “check items”, “causes”, and “troubleshooting” blocks. The questions and check items are used to pinpoint high probability causes by simple inspection or from phenomena without using troubleshooting tools. Next, troubleshooting tools or direct inspection are applied to check the narrowed causes in order from the most probable one to make final confirmation according to the troubleshooting procedure. [Questions]: Items to be drawn from the user or operator. They correspond to A and B in the chart on the right. The items in A are basic ones. The items in B can be drawn from the user or operator, depending on their level. [Check items]: Items to be simply checked by the serviceman to narrow down causes. They correspond to C in the chart on the right. [Causes]: Items to be narrowed from the questions and check items. The serviceman narrows down the probable causes from A, B, and C. [Troubleshooting]: Items to finally verify whether the narrowed down causes are undoubtedly the real causes using the troubleshooting tools and direct inspections.

12-24

95 SERIES

TROUBLESHOOTING

METHOD OF USING TROUBLESHOOTING CHARTS

Items listed in the [Questions] and [Check items] and related to the [Causes] are marked with E, Q, or w. E: Causes to be referred to for questions and check items Q: Causes related to questions and check items w: Causes highly probable among ones marked with Q a When narrowing the “causes”, apply the items marked with w before those marked with Q. When narrowing the causes, do not apply the items marked with E. (If no items have other marks and the causes cannot be narrowed, however, you may apply them.)

95 SERIES

12-25

TROUBLESHOOTING

METHOD OF USING TROUBLESHOOTING CHARTS

<Example of troubleshooting> Exhaust gas is black Let us assume that [Clogged air cleaner] is taken to be the cause of black exhaust gas. 3 symptoms have causal relationship with this problem: [Color of exhaust gas gradually became black], [Power was lost gradually], and [Air cleaner clogging caution lamp is flashing].

12-26

95 SERIES

TROUBLESHOOTING

METHOD OF USING TROUBLESHOOTING CHARTS

If we look from these 3 symptoms to find the causes, we find that there is a relationship with 5 causes. Let us explain here the method of using this causal relationship to pinpoint the most probable cause.

95 SERIES

12-27

TROUBLESHOOTING

POINTS ON TROUBLESHOOTING

POINTS ON TROUBLESHOOTING k When troubleshooting a machine, stop it in a level ground, and check that the lock pin, chocks, and

parking brake are securely fitted.

k When carrying out the operation with two or more workers, keep strictly to the agreed signals, and

do not allow any unauthorized person to come near.

k If the radiator cap is removed when the engine is hot, hot coolant may spurt out and cause burns,

so be sure to wait for the engine to cool down before starting troubleshooting.

k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.

k When disconnecting wiring, always disconnect the negative (–) terminal of the battery first.

k When removing the plug or cap from a location which is under pressure from oil, water, or air,

always release the internal pressure first. When installing measuring equipment, be sure to connect it properly. The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent reoccurrence of the failure. When carrying out troubleshooting, an important point is of course to understand the structure and function. However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea of possible causes of the failure that would produce the reported symptoms. 1. When carrying out troubleshooting, do not hurry to disassemble the components. If components are disassembled immediately after any failure occurs: • Parts that have no connection with the failure or other unnecessary parts will be disassembled. • It will become impossible to find the cause of the failure. It will also cause a waste of manhours, parts, or oil or grease, and at the same time, will also lose the confidence of the user or operator. For this reason, when carrying out troubleshooting, it is necessary to carry out thorough prior investigation and to carry out troubleshooting in accordance with the fixed procedure. 2. Points to ask user or operator 1) Have any other problems occurred apart from the problem that has been reported? 2) Was there anything strange about the machine before the failure occurred? 3) Did the failure occur suddenly, or were there problems with the machine condition before this? 4) Under what conditions did the failure occur? 5) Had any repairs been carried out before the failure? When were these repairs carried out? 6) Has the same kind of failure occurred before?

3. Check before troubleshooting 1) Check for symptoms of any abnormality in the machine and engine. 2) Be sure to check the CHECKS BEFORE STARTING items. 3) Check other inspection items, if necessary. 4) Some other maintenance items can be checked externally, so check any item that is considered to be necessary. 5) Check the controller for display of an error. 4. Confirming failure Confirm the extent of the failure yourself, and judge whether to handle it as a real failure or as a problem with the method of operation, etc. a When operating the machine or engine to reenact the troubleshooting symptoms, do not carry out any investigation or measurement that may make the problem worse. 5. Troubleshooting Use the results of the investigation and inspection in Items 2 – 4 to narrow down the causes of failure, then use the troubleshooting matrix to locate the position of the failure exactly. a The basic procedure for troubleshooting is as follows. 1) Start from the simple points. 2) Start from the most likely points. 3) Investigate other related parts or information. 6. Measures to remove root cause of failure Even if the failure is repaired, if the root cause of the failure is not repaired, the same failure will occur again. To prevent this, always investigate why the problem occurred. Then, remove the root cause.

12-28

95 SERIES

TROUBLESHOOTING

S-1

S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME) General causes why starting performance is poor • Defective electrical system • Insufficient supply of fuel • Insufficient intake of air • Improper selection of fuel (At ambient temperature of –10ºC or below, use ASTM D975 No. 1, and –10ºC or above, use ASTM D975 No. 2 diesel fuel.) a Charging rate or battery.

95 SERIES

Defective CSD(*)

Clogged fuel tank air breather hole

Leakage, clogging, air in fuel system

Defective injection pump (plunger stuck)

Defective injection timing

Defective injection nozzle

Defective or deteriorated battery

Defective alternator

Defective glow plug

Defective regulator

w w w w w Q Q

w w w w Q Q w

w w

Q Q w

w w

w Q w w Q

Q Q

w q q q q

q q q q q q q q q q Adjust

Clean

Repair

Replace

Adjust

q Replace

Remedy

w w

Replace

*: CSD (Cold Starting Device)

Replace

When compression pressure is measured, it is found to be low When air cleaner element is inspected directly, it is found to be clogged When fuel filter, strainer are inspected directly, they are found to be clogged When feed pump strainer is inspected directly, it is found to be clogged Glow plug does not become warm Yes Voltage is 10 – 14 V between alternator terminal B and terminal E with engine at low idle No Either specific gravity of electrolyte or voltage of battery is low Speed of some cylinders does not change when operating on reduced cylinder When checking, injection timing is found to be incorrect When blind plug at rear of pump is removed, it can be seen that plunger control sleeve does not move When fuel cap is inspected directly, it is found to be clogged CSD (*) does not work

E E E w w Q Q Q

Replace

The specific gravity should be for the charging rate of 70% or more in the above table. In cold weather the specific gravity must be for the charging rate of at least 75% in the above table. Confirm recent repair history Degree of use Operated for long period Gradually became worse Ease of starting Starts when warm Indicator lamp does not light up Engine oil must be added more frequently Replacement of filters has not been carried out according to Operation manual Dust indicator is red Non-specified fuel has been used Battery charge lamp is ON Starting motor cranks engine slowly When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Engine does not pick up smoothly, and combustion is irregular Blow-by gas is excessive Match marks on fuel injection pump are out of alignment Mud is stuck to fuel tank cap When engine is cranked with starting motor, 1) Little fuel comes out even when injection pump sleeve nut is loosened 2) Little fuel comes out even when fuel filter air bleed plug is loosened Leakage from fuel piping There is hunting from engine (rotation is irregular) Engine misfires

Clogged feed pump strainer

1.22 1.23 1.24

Clean

1.23 1.24 1.25

Replace

1.24 1.25 1.26

Clogged fuel filter, strainer

1.26 1.27 1.28

Clogged air cleaner element

1.28 1.29 1.30

Clean

70%

Defective contact of valve, valve seat

75%

Worn piston ring, cylinder

80%

Clean

Troubleshooting

Check items

Questions

•

90%

Repair

•

100%

Replace

Charging rate Ambient temperature 20ºC 0ºC –10ºC

Causes

12-29

TROUBLESHOOTING

S-2

S-2 Engine does not start 1) Engine does not turn

Defective starting switch

Defective fuel cut solenoid valve

Defective battery terminal connection

Defective battery relay

Defective safety relay or safety switch

Broken ring gear

Horn sound level is low

Rotating speed is slow

w w

Makes grating noise

Soon disengages again Q Q

Specify gravity of electrolyte, voltage of battery is low For the following conditions 1) – 5), turn the starting switch OFF, connect the cord, and carry out troubleshooting at ON 1) When terminal B and terminal C of starting switch are connected, engine starts 2) When terminal B and terminal C of starting motor are connected, engine starts 3) When terminal B and terminal C of safety relay are connected, engine starts 4) When terminal of safety switch and terminal B of starting motor are connected, engine starts 5) There is no 12 V voltage between terminal B and terminal E of battery relay When ring gear is inspected directly, tooth surface is found to be chipped Remedy

w w w

w q

q q q q q q Replace

When battery is checked, battery electrolyte is found to be low

Replace

When starting switch is turned ON, linkage does not move

Replace

Battery terminal is loose

—

When starting switch is turned ON, there is no clicking sound

Carry out troubleshooting for defective wiring of starting circuit

w Q

Replace

Makes rattling noise and does not turn

12-30

Replace

Condition of horn when starting switch is turned ON

E w

Replace

Operated for long period Horn does not sound

Replace

Degree of use

When starting switch is turned to START, pinion does not move out Check items

Defective starting motor

Confirm recent repair history

When starting switch is turned to START, pinion moves out, but

Troubleshooting

Defective or deteriorated battery

Defective wiring of starting circuit

Causes

Replace

Questions

General causes why engine does not turn • Internal parts of engine seized a If internal parts of the engine are seized, carry out troubleshooting for "Engine stops during operations". • Failure in power train • Defective electrical system

95 SERIES

TROUBLESHOOTING

S-2

2) Engine turns but no exhaust gas comes out (Fuel is not being injected) General causes why engine turns but no exhaust gas comes out • Supply of fuel is impossible • Supply of fuel is extremely small • Improper selection of fuel (particularly in winter)

No. 1

Improper fuel used

ASTM D975 No. 2 Diesel fuel

Clogged fuel tank air breather hole

20 30°C

Clogged, leaking fuel piping

Lack of fuel

Clogged feed pump strainer

−20 −10

Clogged fuel filter, strainer

Ambient temperature

Type of fuel

Seized, broken feed pump piston

Standards for use of fuel

Defective injection pump (plunger seized)

Broken injection pump drive shaft, key

Causes

Questions

Confirm recent history Degree of use

E E

Operated for long period

w w w

Replacement of filters has not been carried out according to operation manual

w w

Fuel tank is found to be empty

There is leakage from fuel piping

Mud is stuck to fuel tank cap

When starting switch is turned ON, linkage does not move

When fuel filter is drained, fuel does not come out 1) Injection pump coupling does not rotate

2) No fuel comes out even when fuel filter air bleed plug is loosened

3) No fuel spurts out even when injection pipe sleeve nut is loosened

w w w

Q Q Q Q

Rust and water are found when fuel is drained q

Check injection pump directly When blind plug at rear of pump is removed, it can be seen that plunger control sleeve does not move

q q

Check feed pump directly

When fuel filter, strainer are inspected directly, they are found to be clogged

q q

When feed pump strainer is inspected directly, it is found to be clogged

95 SERIES

Add

Clean

Replace

Remedy

Replace

q q

When fuel cap is inspected directly, it is found to be clogged

Repair

Troubleshooting

Repair

Check items

When engine is cranked with stating motor,

12-31

TROUBLESHOOTING

S-2

3) Exhaust gas comes out but engine does not start (Fuel is being injected) General causes why exhaust gas comes out but engine does not start • Lack of rotating force due to defective electrical system • Insufficient supply of fuel • Insufficient intake of air • Improper selection of fuel

Defective CSD(*)

Improper fuel used

Clogged fuel tank cap air breather hole

Clogged injection nozzle, defective spray

Leakage, clogging, air in fuel system

Defective or deteriorated battery

Defective glow plug

Clogged air cleaner element

Clogged feed pump strainer

Clogged fuel filter, strainer

Defective piston ring, cylinder

Defective injection pump (plunger stuck)

Defective, broken valve system (valve, rocker lever, etc.)

Causes

Confirm recent history

Questions

Degree of use

E E E

Operated for long period

Suddenly failed to start

w w

When engine is cranked, abnormal noise is heard from around head

Engine oil must be added more frequently

w w

Non-specified fuel has been used

Replacement of filters has not been carried out according to operation manual

w w w

Rust is found when fuel tank is drained

w w w

Dust indicator is red Indicator lamp does not light up

Starting motor cranks engine slowly

Mud is stuck to fuel tank cap When engine is cranked with starting motor, w w w

2) Little fuel comes out even when fuel filter air bleed plug is loosened

Q w

There is leakage from fuel piping When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low

w w

When fuel filter is drained, no fuel comes out

Engine misfires q

Remove head cover and check directly

When compression pressure is measured, it is found to be low

Troubleshooting

When fuel filter, strainer are inspected directly, they are found to be clogged

q q

When feed pump strainer is inspected directly, it is found to be clogged

When air cleaner element is inspected directly, it is found to be clogged

Glow plug mount does not become warm

Either specific gravity of electrolyte or voltage of battery is low

When feed pump is operated, there is no response or pump is heavy

Speed of some cylinders does not change when operating on reduced cylinder

When fuel cap is inspected directly, it is found to be clogged

12-32

Replace

Clean

Repair

Replace

Clean

Replace

Remedy

Replace

*: CSD (Cold Starting Device)

Replace

CSD(*) does not work

Adjust

Check items

1) Little fuel comes out even when injection pipe sleeve nut is loosened

95 SERIES

TROUBLESHOOTING

S-3

S-3 Engine does not pick up smoothly (Follow-up is poor)

General causes why engine does not pick up smoothly • Insufficient intake of air • Insufficient supply of fuel • Improper condition of fuel injection • Use of improper fuel

Defective contact of valve, valve seat

Clogged, leaking fuel piping

Clogged fuel tank air breather hole

Improper valve clearance

Seized turbocharger, interference

Worn piston ring, cylinder

Seized injection pump plunger

Clogged injection nozzle, defective spray

Clogged feed pump strainer

Clogged fuel filter, strainer

Clogged air cleaner element

Causes

Confirm recent repair history E E E

Operated for long period

w w w

Replacement of filters has not been carried out according to operation manual

w w w w

Non-specified fuel has been used

Engine oil must be added more frequently w w

Rust and water are found when fuel is drained w

Dust indicator is red

Noise of interference is heard from around turbocharger Q

Engine pick-up suddenly became poor

Q Q

Blue under light load w

Black

Q w

Clanging sound is heard from around cylinder head

Mud is stuck to fuel tank cap

Check items

There is leakage from fuel piping High idle speed under no load is normal, but speed suddenly drops when load is applied

w w

There is hunting from engine (rotation is irregular)

Q w Q

When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low

w Q w

Blow-by gas is excessive q

When air cleaner element is inspected directly, it is found to be clogged

When fuel filter, strainer are inspected directly, they are found to be clogged

Troubleshooting

When feed pump strainer is inspected directly, it is found to be clogged

Speed of some cylinders does not change when operating on reduced cylinders When blind plug at rear of pump is removed, it can be seen that plunger control sleeve does not move

q q

When compression pressure is measured, it is found to be low

q q

When turbocharger is rotated by hand, it is found to be heavy

When valve clearance is checked directly, it is found to be outside standard value

When fuel cap is inspected directly, it is found to be clogged

95 SERIES

Clean

Adjust

Replace

Repair

Clean

Remedy

Clean

When feed pump is operated, operation is too light or too heavy

Replace

Color of exhaust gas

Repair

Questions

Degree of use

12-33

TROUBLESHOOTING

S-4

S-4 Engine stops during operations

General causes why engine stops during operations • Seized parts inside engine • Insufficient supply of fuel • Overheating a If there is overheating and insufficient output, carry out troubleshooting for overheating. • Failure in power train a If the engine stops because of a failure in the power train, carry out troubleshooting for the chassis.

Failure in chassis power train

Clogged fuel tank air breather hole

Clogged, leaking fuel piping

Broken, seized feed pump piston

Clogged feed pump strainer

Clogged fuel filter, strainer

Lack of fuel

Broken fuel pump drive shaft, key

Broken pump auxiliary equipment

Broken, seized gear train

Broken valve system (valve, rocker lever, etc.)

Broken, seized crankshaft bearing

Broken, seized piston, connecting rod

Causes

Confirm recent repair history

Condition when engine stopped

E E

Operated for long period Abnormal noise was heard and engine stopped suddenly

w w w w w w

Engine overheated and stopped

w Q

Engine stopped slowly

w Q Q

There was hunting and engine stopped

w Q Q

Fuel gauge lamp lights up

Fuel tank is found to be empty

Replacement of filters has not been carried out according to operation manual

w w

Non-specified fuel has been used

Q Q Q

When feed pump is operated, there is no response or it is heavy

Q Q

w w

Mud is stuck to fuel tank cap

Engine turns, but stops when transmission control lever is operated w w w w w

Shaft does not turn

w w

Rust and water are found when fuel is drained Metal particles are found when oil is drained

w w

Remove oil pan and check directly

q q

Q Q

Remove head cover and check directly

When gear train is inspected, it does not turn

Turns when pump auxiliary equipment is removed

When fuel filter, strainer are inspected directly, they are found to be clogged

When feed pump strainer is inspected directly, it is found to be clogged

Clean

Add

Replace

Remedy

Clean

Check feed pump directly

12-34

Carry out troubleshooting in chassis volume

Moves amount of backlash

Repair

Try to turn by hand using barring tool

Replace

Troubleshooting

Check items

Does not turn at all Turns in opposite direction

—

Questions

Degree of use

95 SERIES

TROUBLESHOOTING

S-5

S-5 Engine does not rotate smoothly

General causes why engine does not rotate smoothly (hunting) • Air in fuel system • Defective governor mechanism

Clogged fuel tank air breather hole

Clogged, air in circuit between feed pump and nozzle

Clogged, air in circuit between fuel tank and feed pump

Clogged fuel filter, strainer

Clogged feed pump strainer

Lack of fuel

Low speed is too low

Defective adjustment of governor

Defective operation of governor

Causes

Confirm recent repair history

Condition of hunting

E E

Operated for long period Occurs at fixed speed range

w w Q

Occurs at low idle

Occurs even when speed is raised

Q Q

Q Q Q Q Q w

Occurs on slopes

Fuel tank is found to be empty Replacement of filters has not been carried out according to operation manual

w w

Rust is found when fuel is drained

Q Q

Leakage from fuel piping

w w

When feed pump is operated

w w w

2) No response, light, return is normal Engine speed sometimes rises too high

w w

Sometimes it is difficult to stop engine

w w w q

When governor lever is moved it is found to be stiff

When injection pump is tested, governor is found to be improperly adjusted

When fuel cap is inspected directly, it is found to be clogged

q q

When feed pump strainer is inspected directly, it is found to be clogged

95 SERIES

Clean

Repair

Clean

Add

Adjust

Remedy

Clean

When fuel filter, strainer are inspected directly, they are found to be clogged Adjust

Troubleshooting

Seal on injection pump has come off

Adjust

Check items

1) No response, light, return is quick

Repair

Questions

Degree of use

12-35

TROUBLESHOOTING

S-6

S-6 Engine lacks output (no power)

General causes why engine lacks output • Insufficient intake of air • Insufficient supply of fuel • Improper condition of fuel injection • Use of improper fuel (if non-specified fuel is used, output drops) • Lack of output due to overheating a If there is overheating and insufficient output, carry out troubleshooting for overheating.

Clogged fuel tank air breather hole

Clogged, leaking fuel piping

Bent fuel lever linkage, defective adjustment

Defective contact of valve, valve seat

Improper valve clearance

Seized injection pump plunger

Clogged injection nozzle, defective spray

Clogged feed pump strainer

Clogged fuel filter, strainer

Worn piston ring, cylinder

Seized turbocharger, interference

Clogged air cleaner element

Causes

Confirm recent repair history

Power was lost

Operated for long period

E E E

Q Q Q Q

Suddenly Q

Gradually

Engine oil must be added more frequently w

Replacement of filters has not been carried out according to operation manual

w w w w w w

Non-specified fuel has been used w

Dust indicator is red Color of exhaust gas

w w

Black

Blue under light load w

Noise of interference is heard from around turbocharger

Blow-by gas is excessive w

Check items

Engine pickup is poor and combustion is irregular

Q Q

w w

High idle speed under no load is normal, but speed suddenly drops when load is applied When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low

w Q Q Q

There is hunting from engine (rotation is irregular)

Q Q w

Clanging sound is heard from around cylinder head Q

High idle speed of engine is low

w w

Leakage from fuel piping q

When air cleaner element is inspected directly, it is found to be clogged

When turbocharger is rotated by hand, it is found to be heavy

Troubleshooting

When compression pressure is measured, it is found to be low

q q

When fuel filter, strainer are inspected directly, they are found to be clogged

When feed pump strainer is inspected directly, it is found to be clogged

Speed of some cylinders does not change when operating on reduced cylinder

When valve clearance is checked directly, it is found to be outside standard value

When lever is placed at FULL position, it does not contact stopper

When feed pump is operated, operation is too light or too heavy

12-36

Repair

Adjust

Replace

Adjust

Replace

Repair

Clean

Replace

Clean

Remedy

Replace

When fuel cap is inspected directly, it is found to be clogged

Clean

Questions

Degree of use

95 SERIES

TROUBLESHOOTING

S-7

S-7 Exhaust gas is black (incomplete combustion)

General causes why exhaust gas is black • Insufficient intake of air • Improper condition of fuel injection • Excessive injection of fuel

Defective injection pump (rack, plunger seized)

Defective contact of valve, valve seat

Leakage of air between turbocharger and head

Crushed, clogged muffler

Improper valve clearance

Defective injection pump (excessive injection)

Improper injection timing

Clogged, seized injection nozzle

Worn piston ring, cylinder

Clogged air cleaner element

Seized turbocharger, interference

Causes

Confirm recent repair history E E E

Operated for long period w

Gradually became black

Q w

Engine oil must be added more frequently w

Suddenly

Q Q

Gradually

Noise of interference is heard from around turbocharger

Dust indicator is red

Blow-by gas is excessive Q

Engine pickup is poor and combustion is irregular

When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low

Q Q Q

Q w w

Seal on injection pump has come off

Clanging sound is heard from around cylinder head Q

Exhaust noise is abnormal

w w

Muffler is crushed

Leakage of air between turbocharger and head, loose clamp q

When turbocharger is rotated by hand, it is found to be heavy

When air cleaner is inspected directly, it is found to be clogged

When compression pressure is measured, it is found to be low

q q

Speed of some cylinders does not change when operating on reduced cylinders

When checking, injection timing is found to be incorrect

Injection pump test shows that injection amount is incorrect

When valve clearance is checked directly it is found to be outside standard value

q Adjust

Adjust

Replace

Clean

Remedy

Replace

When muffler is removed, exhaust color returns to normal

Replace

Troubleshooting

Match marks on fuel injection pump are out of alignment

95 SERIES

Q Q Q

Non-specified fuel has been used

Check items

Blue under light load

Power was lost

Replace

Color of exhaust gas

Repair

Questions

Suddenly became black

Replace

Degree of use

12-37

TROUBLESHOOTING

S-8

S-8 Oil consumption is excessive (or exhaust gas is blue) a Do not run the engine at idle for more than 20 minutes continuously. (Both low and high idle) General causes why oil consumption is excessive • Abnormal combustion of oil • External leakage of oil • Wear of lubrication system

Worn valve (stem, guide), broken seal

Dust sucked in from intake system

Worn, broken rear seal, seal surface

Turbocharger Worn seal at blower end

Worn seal at turbine end

Broken oil cooler

Leakage from oil pan, cylinder head, etc.

Leakage from oil drain plug

Leakage from oil piping

Leakage from oil filter, oil cooler

Clogged breather or breather hose

Worn piston ring, cylinder liner

Broken piston ring

Causes

Degree of use

Operated for long period w

Oil consumption suddenly increased Engine oil must be added more frequently

Engine oil becomes contaminated quickly

Q w Q Q

w w

Abnormally excessive

None

w w w w

Area around engine is dirty with oil

There is oil in engine coolant Check items

w w

Exhaust gas is blue under light load Amount of blow-by gas

E E Q

When exhaust pipe is removed, inside is found to be dirty with oil

Q w

Inside of turbocharger intake pipe is dirty with oil

Oil level in clutch or TORQFLOW transmission damper chamber rises

Clamps for intake system are loose q q

When compression pressure is measured, it is found to be low

Troubleshooting

When breather element is inspected, it is found to be clogged with dirty oil

q q q q

There is external leakage of oil from engine

Pressure-tightness test of oil cooler shows there is leakage

q q

Excessive play of turbocharger shaft

Check rear seal directly

When intake manifold is removed, dust is found inside

12-38

Repair

Replace

Repair

Clean

Replace

Remedy

Replace

When intake manifold is removed, inside is found to be dirty with oil

Repair

Questions

Confirm recent repair history

95 SERIES

TROUBLESHOOTING

S-9

S-9 Oil becomes contaminated quickly

General causes why oil becomes contaminated • Intake of exhaust gas due to internal wear • Clogging of lubrication passage • Improper combustion • Use of improper oil • Operation under excessive load

Exhaust gas is black

Defective seal at turbocharger turbine end

Clogged turbocharger drain pipe

Q Q

Engine oil must be added more frequently

Non-specified oil is being used w

Blue under light load

Black w

Abnormally excessive

None

Oil filter caution lamp stays on even when oil pressure rises Q

When oil filter is inspected, metal particles are found

w Q w

When exhaust pipe is removed, inside is found to be dirty with oil

Engine oil temperature rises quickly q

When compression pressure is measured, it is found to be low When breather element is inspected directly, it is found to be clogged with dirty oil, or hose is broken

q q q

When oil filter is inspected directly, it is found to be clogged

When oil cooler is inspected directly, it is found to be clogged

Turbocharger drain tube is clogged

95 SERIES

Clean

Replace

Clean

Remedy

Replace

Excessive play of turbocharger shaft

Carry out troubleshooting for "Exhaust gas is black".

Amount of blow-by gas

Troubleshooting

Clogged oil cooler

Worn valve, valve guide

Clogged oil filter

Operated for long period

—

Degree of use

Color of exhaust gas

Check items

Clogged breather, breather tube

Confirm recent repair history

Replace

Questions

Worn piston ring, cylinder

Causes

12-39

TROUBLESHOOTING

S-10

S-10 Fuel consumption is excessive

General causes why fuel consumption is excessive • Leakage of fuel • Improper condition of fuel injection • Excessive injection of fuel

Defective CSD(*)

Defective adjustment of fuel lever linkage

Defective oil seal inside feed pump (piston)

Leakage of fuel inside head cover

External leakage from fuel piping, fuel filter

Improper fuel injection timing

Defective injection pump plunger

Defective injection nozzle spray

Defective injection pump (excessive injection)

Causes

Degree of use

E E

Operated for long period More than for other machines of same model

Condition of fuel consumption

E Q

Q Q

Gradually increased

Q Q

Suddenly increased Exhaust gas color

w Q

Black

Check items

Q Q

White

Seal on injection pump has come off There is irregular combustion

When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low

w Q w

Match mark on injection pump is misaligned

There is external leakage of fuel from engine Engine oil level rises and smells of diesel fuel

Engine low idle speed is high

Injection pump test shows that injection amount is incorrect

w w w

Speed of some cylinders does not change when operating on reduced cylinders Troubleshooting

When blind plug at rear of pump is removed, it can be seen that plunger control sleeve does not move

q q

When checking, fuel injection timing is found to be incorrect

Remove head cover and check directly

Remove feed pump and check directly

When engine speed is measured, low idle speed is found to be high

12-40

Adjust

Repair

Adjust

Replace

Remedy

Adjust

(*) CSD (Cold Starting Device)

Replace

CSD (*) does not move

Adjust

Questions

Confirm recent repair history

95 SERIES

TROUBLESHOOTING

S-11

S-11 Oil is in coolant, or coolant spurts back, or coolant level goes down

General causes why oil is in coolant • Internal leakage in lubrication system • Internal leakage in cooling system

Internal cracks in cylinder block

Broken liner O-ring, holes caused by pitting

Broken oil cooler for power train

Insufficient protrusion of liner

Broken head, head gasket

Confirm recent repair history E

Suddenly increased

Q Q

Q Q Q

Gradually increased Q

Engine oil level has risen, oil is cloudy white

Check items

Hard water is being used as cooling water Excessive air bubbles inside radiator, spurts back

Pressure-tightness test of oil cooler shows there is leakage

Q Q Q w w

Hydraulic oil, torque converter transmission oil is cloudy white

When hydraulic oil, torque converter transmission oil is drained, water comes out

q q

Pressure-tightness test of cylinder head shows there is leakage

Remove cylinder head and check directly

q q

95 SERIES

Replace

Remedy

Replace

Remove oil pan and check directly

Replace

Increase in oil level

Operated for long period

Replace

Degree of use

Troubleshooting

Questions

Broken oil cooler core, O-ring

Causes

12-41

TROUBLESHOOTING

S-12

S-12 Oil pressure lamp lights up (drop in oil pressure)

General causes why oil pressure lamp lights up • Leakage, clogging, wear of lubricating system • Defective oil pressure control • Use of improper oil (improper viscosity) • Deterioration of oil due to overheating

Water, fuel in oil

Defective oil pressure sensor

SAE 15W-40

Defective oil level sensor

SAE 10W-30

Leaking, crushed hydraulic piping

SAE 10W Engine oil

Defective relief valve

Clogged oil filter

SAE 30

Defective regulator valve

20 30°C

Insufficient oil in oil pan

Defective oil pump

Broken suction pipe brazing

Selection of oil SAE number according to ambient temperature Worn bearing journal

Type of oil

Clogged strainer inside oil pan

a Standards for engine oil selection

Clogged, broken oil pipe inside oil pan

Causes

E E

Operated for long period

Replacement of filters has not been carried out according to operation manual

Caution lamp lights up

Non-specified fuel has been used

w Q

Q w

Lights up at low idle Condition when oil pressure lamp lights up

Q w w w w Q Q Q

Lights up at low, high idle

Lights up on sloes

w w

Sometimes lights up

Check items

Q Q w

There is clogging, leakage from hydraulic piping (external) Oil level sensor lamp lights up

When oil level in oil pan is checked, it is found to be low

Metal particles are found when oil is drained

Metal particles are stuck to oil filter element

Q Q

Oil is cloudy white or smells of diesel oil q q q q q

Remove oil pan and check directly

Oil pump rotation is heavy, there is play

q q

There is catching of relief valve, regulator valve, spring, valve guide is broken

When oil level sensor is replaced, oil pressure sensor lamp goes out

12-42

Repair

Replace

Adjust

Add

Replace

Repair

Clean

Remedy

Clean

When oil pressure is measured, it is found to be within standard value

Replace

Troubleshooting

When oil filter is inspected directly, it is found to be clogged

Carry out troubleshooting for "Oil level rises".

Degree of use

—

Questions

Confirm recent repair history

95 SERIES

TROUBLESHOOTING

S-13

S-13 Oil level rises

If there is oil in the coolant, carry out troubleshooting for "Oil is in coolant". • Water in oil (cloudy white) • Fuel in oil (diluted, and smells of diesel fuel) • Entry of oil from other component

Operated for long period

Check items

Cracks inside cylinder block

Damaged liner O-ring, holes made by pitting

Defective thermostat seat

Defective injection pump inside (flange type)

Leakage of fuel from piping inside head cover

Defective seal of pump or auxiliary equipment

Worn, damaged rear seal surface

Clogged water pump breather hole, defective seal

E E E

w Q Q

There is oil in radiator coolant Exhaust gas is white

When engine is first started, drops of water come from muffler

Q Q Q

Water pump breather hole is clogged with mud

When water pump breather hole is clean, water comes out

w w

Oil level goes down in clutch, TORQFLOW transmission, or damper chamber

Oil level goes down in hydraulic tank Engine oil smells of diesel fuel

w w w

Fuel is added more frequently

w w w q

Pressure-tightness test of oil cooler shows there is leakage

Pressure-tightness test of cylinder head shows there is leakage

When compression pressure is measured, it is found to be low

Remove water pump and check directly

Check rear seal directly

When pump auxiliary equipment is removed, seal is found to be broken

Remove head cover and check directly

Remove injection pump and check directly

There is improper contact of thermostat seat valve

q q

95 SERIES

Repair

Replace

Repair

Replace

Repair

Replace

Remedy

Replace

Remove oil pan and check directly

Replace

Degree of use

Leave radiator cap open. When engine is run at idle, an abnormal number of bubbles appear, or water spurts back

Troubleshooting

Broken head, head gasket (including precombustion chamber)

Defective nozzle holder sleeve

Confirm recent repair history

Replace

Questions

Broken oil cooler core, O-ring

Causes

12-43

TROUBLESHOOTING

S-14

S-14 Coolant temperature becomes too high (overheating)

General causes why coolant temperature becomes too high • Lack of coolant (deformation, damage of fan) • Drop in heat dissipation efficiency • Defect in cooling circulation system • Rise in oil temperature of power train a Carry out troubleshooting for chassis.

Rise in torque converter oil temperature

Damaged liner O-ring, holes made by pitting

Broken head, head gasket

Defective pressure valve

Clogged, broken oil cooler

Fan belt slipping, worn fan pulley

Insufficient coolant

Defective coolant temperature gauge

Defective thermostat (does not open)

Clogged radiator core

Clogged, crushed radiator fins

Broken water pump

Causes

Confirm recent repair history

Coolant temperature gauge

E E

Suddenly overheated

Q Q w w Q

Always tends to overheat

Rises quickly

Q w

Does not go down from red range

Radiator coolant level sensor lights up

Fan belt whines under sudden load

Cloudy white oil is floating on coolant

Coolant flows out from overflow hose

Excessive air bubbles inside radiator, coolant spurts back Q

Engine oil level has risen, oil is cloudy white

Check items

There is play when fan pulley is rotated Radiator shroud, inside of underguard are clogged with dirt or mud

When light bulb is held behind radiator, no light passes through

w w

Coolant is leaking because of cracks in hose or loose clamps

Belt tension is found to be slack

Power train oil level enters red range before engine coolant temperature q

Temperature difference between top and bottom radiator tanks is excessive

q q

When coolant filler port is inspected, the core is found to be clogged When function test is carried out on the thermostat, it does not open even at cracking temperature

q q

When coolant temperature is measured, it is found to be normal

When oil cooler is inspected directly, it is found to be clogged

When measurement is made with radiator cap tester, set pressure is found to be low

When compression pressure is measured, it is found to be low

12-44

Replace

Repair

Add

Replace

Repair

Remedy

Replace

Remove oil pan and inspect directly

Replace

Troubleshooting

Temperature difference between top and bottom radiator tanks is slight

Carry out troubleshooting for chassis.

Condition of overheating

E E

Operated for long period

—

Questions

Degree of use

95 SERIES

TROUBLESHOOTING

S-15

S-15 Abnormal noise is made

Judge if the noise is an internal noise or an external noise. General causes why abnormal noise is made • Abnormality due to defective parts • Abnormal combustion noise • Air sucked in from intake system

Defect inside muffler (dividing board out of position)

Leakage of air between turbocharger and head

Improper gear train backlash

Broken valve system (valve, rocker lever, etc.)

Improper adjustment of valve clearance

Deformed fan, interference of fan belt

Defective injection pump (excessive injection)

Defective injection pump (rack, plunger seized)

Clogged, seized injection nozzle

Missing, seized bushing

Seized turbocharger, interference

Worn piston ring, cylinder liner

Causes

Degree of use Condition of abnormal noise

Operated for long period

Gradually occurred

Q Q Q

Suddenly occurred

Q Q

Non-specified fuel has been used w

Engine oil must be added more frequently Color of exhaust gas

Blue under light load

Black

Metal particles are found in oil filter

Blow-by gas is excessive

w w

Noise of interference is heard from around turbocharger

Check items

Engine pickup is poor and combustion is irregular

When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low

w Q w

Seal on injection pump has come off

Q Q Q Q Q

Abnormal noise is loud when accelerating engine

w w

Clanging sound is heard from around cylinder head

Leakage of air between turbocharger and head, loose clamp

Vibrating noise is heard from around muffler q

When compression pressure is measured, it is found to be low

When turbocharger is rotated by hand, it is found to be heavy

Troubleshooting

Remove gear cover and check directly

q q

Speed of some cylinders does not change when operating on reduced cylinders When blind plug at rear of pump is removed, it can be seen that plunger control sleeve does not move

q q

Injection pump test shows that injection amount is incorrect

Fan is deformed, or belt is loose

When valve clearance is checked directly, it is found to be outside standard value

Remove cylinder head cover and check directly

95 SERIES

Repair

Replace

Adjust

Repair

Adjust

Replace

Remedy

Replace

When muffler is removed, abnormal noise disappears

Replace

Questions

Confirm recent repair history

12-45

TROUBLESHOOTING

S-16

S-16 Vibration is excessive a If there is abnormal noise together with the vibration, carry out troubleshooting for "Abnormal noise is made". General causes why vibration is excessive • Defective parts (abnormal wear, breakage) • Improper alignment • Abnormal combustion

Defective injection pump (excessive injection)

Valve system (valve, rocker lever, etc.) stuck

Improper gear train backlash

Misalignment between engine and power train

Broken part inside output shaft (damper)

Loose engine mounting bolts, broken cushion

Worn support pilot

Worn balancer, cam bushing

Worn connecting rod, main bearing

Causes

Degree of use Condition of vibration

E E E E

Operated for long period

Suddenly increased Q Q Q Q

Gradually increased

Non-specified fuel has been used

Q Q

Metal particles are found in oil filter

w w

Metal particles are found when oil is drained

w w

Oil pressure is low at low idle

Q Q Q Q

Vibration occurs at mid-range speed

Q Q Q Q Q

Vibration follows engine speed

w Q

Exhaust gas is black

Seal on injection pump has come off q

Remove oil pan and check directly

Remove side cover and check directly Troubleshooting

Check directly for worn support pilot, play

Check directly for loose engine mounting bolts, broken cushion

Check inside of output shaft (damper) directly

When radial runout, face runout are measured, they are found to be outside standard

Remove front cover and check directly

Remove head cover and check directly

12-46

Replace

Repair

Replace

Remedy

Replace

Injection pump test shows that injection amount is incorrect

Adjust

Check items

Questions

Confirm recent repair history

95 SERIES

13 DISASSEMLY AND ASSEMBLY General disassembly .................................................................................................................................... 13- 2 General assembly......................................................................................................................................... 13- 14

a The work procedure may differ slightly from that given here depending upon machine in which the engine is mounted and also the particular stand used, however it is fundamentally the same. a Use correct service tools when performing disassembly and assembly.

95 SERIES

13-1

DISASSEMBLY AND ASSEMBLY

GENERAL DISASSEMBLY

GENERAL DISASSEMBLY Special tools No.

Part No.

Part Name

Q'ty

790-501-5000 or 790-501-2001

Unit repair stand or Engine overhaul stand

790-901-1250

Bracket

795-102-2102

Spring pusher

795-100-4710

Valve guide remover

795-240-2801

Flange puller

795-100-2800

Piston ring tool

•

Preparatory work 1) Remove all dirt and mud from around the engine. 2) Remove the drain plug and drain the oil from the engine. 6

Engine oil: Approx. 9.5 l

3) Prepare a stable stand which will prevent the engine from falling over, then put the engine securely in the stand. 4

Engine assembly: Approx. 300 kg (The weight of the engine differs according to the model of machine on which it is mounted.)

1. Setting in unit repair stand 1) Remove starting motor (1). 2) Install bracket A1 to engine.

3) Install engine assembly (2) in repair stand A.

13-2

95 SERIES

DISASSEMBLY AND ASSEMBLY

GENERAL DISASSEMBLY

2. Fan pulley 1) Loosen mounting bolt of adjustment plate (1), and mounting bolt and nut of alternator. 2) Move alternator towards cylinder block, and remove belt (2). k Be careful not to catch your fingers or damage the alternator when moving the alternator towards the cylinder block. 3) Remove fan pulley (3).

3. Alternator Remove adjustment plate, then remove alternator (1). 4. Oil filter, dipstick guide 1) Remove oil filter (2). 2) Remove dipstick guide (3).

5. Water pump Pull out pilot portion, then remove water pump (1).

6. Turbocharger (S4D95LWE-5) 1) Loosen clamps (1) and (2). 2) Remove bolts (3) and clamps (4). 3) Remove joint bolts (5) and (6). 4) Remove nuts (7), then remove turbocharger (8).

95 SERIES

13-3

DISASSEMBLY AND ASSEMBLY

GENERAL DISASSEMBLY

7. Exhaust manifold Remove exhaust manifold (1).

8. Fuel injection pipe 1) Remove clamp (1). 2) Remove sleeve nut, then remove fuel injection pipe (2).

9. Fuel filter Remove fuel filter (1) and fuel hose (2).

10. Intake manifold Remove intake manifold (1).

13-4

95 SERIES

DISASSEMBLY AND ASSEMBLY

GENERAL DISASSEMBLY

11. Glow wire, glow plug 1) Remove glow wire (1). 2) Remove glow plug (2).

12. Spill tube Remove spill tube (1). 13. Nozzle holder Remove nozzle holder (2). a When removing the nozzle holder, clean around the nozzle holder and fit a blind plug to prevent dust or dirt from entering. a Be careful not to damage the tip of the nozzle holder when removing. a Mark the nozzle holders with tags showing the cylinder No. and keep in a safe place. If there is no abnormality in the nozzle holder, install in the same position when assembling. 14. Cylinder head cover Remove cylinder head cover (3). 15. Rocker arm assembly Remove rocker arm assembly (1). a When removing the rocker arm, loosen the locknut and turn the adjustment screw back 2 - 3 turns.

16. Push rods Remove push rods (1) from cylinder head. a Mark the push rods with tags to show the places of installation and keep in a safe place. If there is no abnormality in the push rod, install in the same position when assembling.

95 SERIES

13-5

DISASSEMBLY AND ASSEMBLY

GENERAL DISASSEMBLY

17. Cylinder head assembly 1) Remove mounting bolts of cylinder head assembly. 2) Fit lifting tool to hanger of cylinder head, then lift off cylinder head assembly (1) with crane. a Lay cardboard on the floor to protect the bottom face of the cylinder head from damage.

a When disassembling the cylinder head assembly, do as follows. i) Using spring pusher B, compress valve spring, then remove valve cotter (2). ii) Loosen spring, and remove spring seat (3) and valve spring (4). iii) Raise cylinder head and remove valve (5). a Mark the valves with tags to show the place of installation and keep in a safe place.

iv)Using remover C, remove valve guide (6).

13-6

95 SERIES

DISASSEMBLY AND ASSEMBLY

GENERAL DISASSEMBLY

18. Fuel injection pump 1) Loosen clamps (1). 2) Remove water hoses (2) for CSD.

3) Remove bracket (3). 4) Remove mounting nuts (4) of fuel injection pump, then remove fuel injection pump (5). a There is one bolt installed from the fuel injection pump side, so do not forget to remove it. a To prevent dirt or dust from entering, fit caps or use tape to cover the oil and fuel inlet and outlet ports.

a Remove cover (6) so that the match marks can be aligned when the fuel injection pump is installed.

19. Oil pan Remove oil pan (1).

95 SERIES

13-7

DISASSEMBLY AND ASSEMBLY

GENERAL DISASSEMBLY

20. Oil suction pipe Remove oil suction pipe (1).

21. Crankshaft pulley 1) Remove plate (1). 2) Set flange puller D in position, then pull out crankshaft pulley (2).

22. Gear case cover Remove gear case cover (1).

23. Front oil seal Remove front oil seal (1).

13-8

95 SERIES

DISASSEMBLY AND ASSEMBLY

GENERAL DISASSEMBLY

24. Oil pump Remove oil pump (1). 25. Idler gear 1) Remove plate (2). 2) Remove idler (3).

26. Camshaft assembly 1) Turn over cylinder block, so that cylinder head mounting face is facing down. 2) Remove mounting bolts (1) through casting hole in gear. 3) Remove camshaft assembly (3) together with thrust plate (2). a When removing, rotate the camshaft lightly and be careful not to damage the bushing.

27. Flywheel 1) Remove coupling (1). 2) Remove flywheel (2). k The pilot is short, so the flywheel may come off suddenly.

28. Flywheel housing Remove flywheel housing (1).

95 SERIES

13-9

DISASSEMBLY AND ASSEMBLY

GENERAL DISASSEMBLY

29. Rear oil seal Remove rear oil seal (1).

30. Piston, connecting rod assembly 1) Checking connecting rod cap number. i) Turn over cylinder block, and set with cylinders horizontal. a Turn the cylinder block over carefully to prevent the tappets from coming out of position. ii) Check that number stamped on connecting rod cap matches cylinder number. a If there is no number stamped on the connecting rod cap, stamp a number at the camshaft end. 2) Removing carbon Using fine sandpaper, remove carbon at top of cylinder. a Be careful not damage the inside of the cylinder. a Measure the end play of connecting rod with a dial gauge before removing the piston and connecting rod assembly. 3) Connecting rod cap i) Rotate crankshaft to set piston at bottom dead center. ii) Remove mounting bolts of connecting rod cap (1). iii) Tap cap with plastic hammer and remove connecting rod cap together with bearing. a Be careful not to damage the thread of the mounting bolts.

13-10

95 SERIES

DISASSEMBLY AND ASSEMBLY

GENERAL DISASSEMBLY

4) Piston, connecting rod assembly Push a wooden bar or hammer handle through from oil pan side. Support piston at cylinder head end, then push bar in further from oil pan side to remove piston and connecting rod assembly (2).

5) Disassembly of piston and connecting rod assembly i) Using pliers [1], remove snap ring (3) on one side. ii) Remove piston pin (4), and separate connecting rod (5) and piston (6). a If the pin does not come out, leave in hot water, then try again. iii) Remove snap ring on other side in the same way.

iv) Using piston ring tool E, remove piston ring (7) from piston.

v) If bushing (8) is worn, remove using push tool [2] (outside diameter: 32 mm). a Keep the pistons, connecting rods, bearings, piston rings, piston pins, and bushings in sets for each cylinder number.

95 SERIES

13-11

DISASSEMBLY AND ASSEMBLY

GENERAL DISASSEMBLY

31. Main bearing cap 1) Measuring end play i) Turn over cylinder block, so that oil pan is facing up. ii) Measure end play of crankshaft using dial gauge [1]. a The end play measurement is necessary for judging wear of the thrust bearing and abnormal wear of the crankshaft, so meas ur e before removing the crankshaft.

2) Main bearing cap i) Remove mounting bolts (1) of main bearing cap. ii) Insert mounting bolt in bolt hole in cap, then shake cap, or tap with plastic hammer on left and right sides, and remove main bearing cap (3) together with lower bearing (2).

a Thrust bearings (4) are assembled on both sides of cap (3) at the flywheel end, so after removing, mark to show the place of installation.

32. Crankshaft 1) Remove crankshaft (1). a Be careful not to hit the crankshaft against the cylinder block and damage the sliding surface.

13-12

95 SERIES

DISASSEMBLY AND ASSEMBLY

GENERAL DISASSEMBLY

2) Remove upper main bearing (2). a Mark the main bearing and thrust bearing with tags to show the place of installation, and keep in a safe place in sets for each cap number.

33. Tappet Remove tappet (1).

95 SERIES

13-13

DISASSEMBLY AND ASSEMBLY

GENERAL ASSEMBLY

GENERAL ASSEMBLY Special tools No.

Part No.

Part Name

Q'ty

790-501-5000 or 790-501-2001

Unit repair stand or Engine overhaul stand

790-901-1250

Bracket

795-102-2102

Spring pusher (KIT)

795-100-2800

Piston ring tool

795-213-1800

Piston holder

795-100-4720

Push tool

795-125-1370

Feeler gauge

1. Setting in unit repair stand 1) Install bracket A1 to cylinder block. 2) Set cylinder block in unit repair stand A.

2. Tappet 1) Turn over cylinder block so that cylinder head side is at bottom. 2) Coat with engine oil and assemble tappet (1).

3. Crankshaft 1) Align protrusion of upper main bearing (2) with notch in cylinder block, then assemble to cylinder block. a Check that there is no dirt or dust stuck to the rear face of the bearing. Coat the inside face of the bearing with engine oil (SAE30) before assembling.

13-14

95 SERIES

DISASSEMBLY AND ASSEMBLY

GENERAL ASSEMBLY

2) Taking care not to hit crankshaft (1) against cylinder block, set crankshaft in mounting position. a If the crankshaft gear has been replaced, insert the crankshaft gear in an electric furnace and heat at 230 – 250°C for about 30 minutes, then shrink fit the gear.

4. Main bearing cap 1) Align protrusion in lower main bearing (2) with notch in cap, then install main bearing cap (3). a Check that there is no dirt or dust stuck to the rear face of the bearing. Coat the inside face of the bearing with engine oil (SAE30) before assembling. 2) Check that number stamped on main bearing cap is the same as number on cylinder block. 3) Set casting number of main bearing cap facing front, and assemble with mounting bolt (1). 4) Align lower thrust bearing (4) with dowel pin, then install in main bearing cap (3). a Assemble two pieces at the top and bottom at the flywheel end, and one piece at the opposite end. a Install each thrust bearing with the oil groove on the outside.

5) Set casting number facing front, and install main bearing cap (3). a Be careful not to let the thrust bearings slip out of place.

95 SERIES

13-15

DISASSEMBLY AND ASSEMBLY

GENERAL ASSEMBLY

6) Tighten mounting bolts of main bearing cap with a torque wrench as follows. a Coat the bolt thread and seat face with engine oil. a When tightening the mounting bolts of the main bearing cap, start in the middle and work to the outside. Tighten to the following torque. 3 Mounting bolt of main bearing cap

Unit: Nm {kgm} Order

Target

Range

1st step

112.8 {11.5}

107.9 – 117.7 {11 – 12}

2nd step

Loosen completely

3rd step

132.4 {13.5}

127.5 – 137.3 {13 – 14}

a After tightening the mounting bolts, c h ec k th at t he c r an k s ha ft r o ta te s smoothly. 7) Measuring end play of crankshaft Put probe of dial gauge [1] in contact with end face of crankshaft. Read movement of gauge when crankshaft is moved forward and backward. a Permissible range of end play: 0.13 – 0.35 mm

5. Piston, connecting rod assembly 1) Assembly of piston and connecting rod assembly. a If the piston and connecting rod assembly has been disassembled, assemble the piston and connecting rod assembly first as follows. i) Using push tool [2] (outside diameter: 32 mm), press fit bushing (8) on connecting rod.

13-16

95 SERIES

DISASSEMBLY AND ASSEMBLY

GENERAL ASSEMBLY

ii) Set rings with stamped mark at end gap facing up (compression ring only), then use piston ring tool E to assemble piston ring (7) on piston (6).

a Be careful not to damage the piston or break the piston rings. a Fit expander (10) in the groove on the inside diameter of oil ring (9) before installing. Check that the expander is completely fitted into the ring groove. a The end gap of the ring should be at 1 8 0 ° t o t h e j o i n o f t h e c o i l i n th e expander.

iii) Using pliers [1], assemble snap ring on one side in snap ring groove of piston.

iv) Set (F) mark on piston pin boss facing in same direction as casting number on connecting rod. Insert piston pin (4), and assemble connecting rod (5) and piston (6). a If it is difficult to insert the piston pin, put the piston in hot water to expand the diameter of the pin hole, then insert the pin. v) Assembly other snap ring on other side of piston. a After assembling the snap rings, c h e c k t h a t t h e c o n n e c ti n g r o d moves smoothly forward and backward. vi) Align protrusion in upper bearing of connecting rod with notch in connecting rod, then install.

95 SERIES

13-17

DISASSEMBLY AND ASSEMBLY

GENERAL ASSEMBLY

2) Turn over cylinder block so that crankshaft is vertical. 3) Set end gaps of piston rings as shown in diagram. 4) Set crankshaft pin at bottom dead center. a Coat the inside face of the cylinder, the piston rings and the surface of connecting rod bearing with engine oil. 5) Align direction of (F) mark on side face of piston to face front of engine. Using piston holder F, insert piston and connecting rod assembly (2) from cylinder head end. 6) When piston rings are inserted inside cylinder, push in head of piston with hand or wooden bar. In addition, pull big end of connecting rod to align with crankshaft pin. 7) Align protrusion of lower bearing with notch in cap, then assemble to bearing cap. a Check that there is no dirt or dust stuck to the rear face of the bearing. 8) Set with stamped mark at camshaft end, then install connecting rod cap (1). a Check the connecting rod bearing with engine oil. a Check that the stamped number on the connecting cap is the same as the number of the cylinder.

13-18

95 SERIES

DISASSEMBLY AND ASSEMBLY

GENERAL ASSEMBLY

a Tighten the connecting rod cap as follows. a Coat the connecting rod bolt thread and seat face with engine oil. 3 Mounting bolt of connecting rod

Unit: Nm {kgm} Order 1st step

2nd step

Target

Range

39.2 {4.0}

39.2 – 41.2 {4.0 – 4.2}

Mark bolt head and cap seat with felt pen, then tighten to following angle. 90°

90° – 120°

a The connecting rod bolts may be reused five times. Make a punch mark on the bolt head each time the bolts are used. If there are already five marks on the bolt head, replace with new bolts. a After assembling the connecting rods, c h e ck t ha t th e c r a nk s h aft r otat es smoothly. 9) Measuring side clearance of connecting rod cap i) Turn over cylinder block so that oil pan faces up. ii) Using dial gauge [3], measure side clearance of connecting rod cap. a Permissible range of side clearance: 0.20 – 0.40 mm

6. Flywheel housing 1) Using push tool [J] (outside diameter: 120 mm), install rear oil seat (2) on flywheel housing (1). 2) After press fitting rear oil seal, fill 40 – 60% of space at seal lip with grease. 2 Rear seal: Grease (G2-LI)

95 SERIES

13-19

DISASSEMBLY AND ASSEMBLY

GENERAL ASSEMBLY

3) Align with dowel pin (3), and install flywheel housing (1). 2 Mounting surface of flywheel housing: Gasket sealant (LG-7) a When fitting the seal lip to the outside diameter of the crankshaft flange, be careful not to apply excessive force to the seal lip surface. 3 Mounting bolt: 66.2 ± 7.4 Nm {6.75 ± 0.75 kgm}

4) Measuring difference in height of mounting surface Measure distance in height between surface for mounting oil pan on cylinder block and flywheel housing. a Permissible difference in height of flywheel housing mounting surface: Max. 0.15 mm

5) Measure radial and face runout of flywheel housing with dial gauge [2]. a Radial runout: Max. 0.30 mm a Face runout: Max. 0.35 mm

7. Flywheel 1) Install flywheel (2). 3 Mounting bolt: 117.7 ± 5 Nm {12.0 ± 0.5 kgm} Unit: Nm {kgm} Order

Target

Range

1st step

107.9 {11}

98.1 – 117.7 {10 – 12}

2nd step

191.2 {19.5}

186.3 – 196.1 {19 – 20}

2) Install coupling (1). 3) Measure radial and face runout of flywheel. a Radial runout: Max. 0.15 mm a Face runout: Max. 0.25 mm

13-20

95 SERIES

DISASSEMBLY AND ASSEMBLY

GENERAL ASSEMBLY

8. Camshaft assembly 1) Insert camshaft assembly (3) into cylinder block. a Rotate the camshaft lightly when inserting to avoid damaging the bushing. 2) Tighten mounting bolts (1) of thrust plate (2) through casting hole of gear to secure camshaft assembly. 3 Mounting bolt of thrust plate: 18.6 ± 5 Nm {1.9 ± 0.5 kgm}

3) Put dial gauge [1] in contact with end face of camshaft. Read movement of gauge when camshaft is moved backward and forward. a End play of camshaft: 0.15 – 0.35 mm

9. Idler gear 1) Align match marks of gear, and install idler gear (3). a Match marks Crankshaft gear (5) and idler gear: "A" Idler gear and cam gear (4): "B" 2) Install plate (2). 3) Tighten mounting bolt (1) of idler gear shaft. 3 Mounting bolt: 110.3 ± 12.3 Nm {11.25 ± 1.25 kgm} 4) Put dial gauge [1] in contact with end face of idler gear. Read movement of gauge when idler gear is moved backward and forward. a End play of idler gear: 0.03 – 0.09 mm

95 SERIES

13-21

DISASSEMBLY AND ASSEMBLY

GENERAL ASSEMBLY

10. Oil pump 1) Install driven gear (1) of oil pump. 2) Install cover (2) and drive gear (3) of oil pump. 3) Measuring end play Measure end play of oil pump gear in same way as measuring end play of camshaft. a Permissible range of end play: 0.02 – 0.07 mm a Measuring backlash of gears Temporarily fit fuel injection pump assembly (1), and measure backlash of gears with dial gauge [1]. a When measuring the backlash of the gears, hold one gear securely, then move the other gear and measure the backlash.

a Backlash of gear (helical gear) Unit: mm Match mark

Position of measurement

Range

A–A

Crankshaft gear and idler gear

0.08 – 0.19

B–B

Camshaft gear and idler gear

0.08 – 0.19

C–C

Injection pump gear and idler gear

0.07 – 0.29

–

Camshaft gear and oil pump gear

0.07 – 0.29

13-22

95 SERIES

DISASSEMBLY AND ASSEMBLY

GENERAL ASSEMBLY

11. Front oil seal 1) Using push tool (outside diameter: 72 mm), install front oil seal (1). 2) After press fitting front oil seal, fill 40 – 60% of space at seal lip with grease. 2 Front oil seal: Grease (G2-LI) 3) Coat mounting surface cylinder block side with gasket sealant. 2 Mounting surface: Gasket sealant (LG-7)

12. Gear case cover 1) Install gear case cover assembly (1). 2) Measuring difference in height of mounting surface Measure distance in height between surface for mounting oil pan on cylinder block and gear case cover. a Permissible difference in height of oil pan mounting surface: Max. 0.15 mm

13. Crankshaft pulley 1) Align with crankshaft key, then install crankshaft pulley (2). 2) Fit plate (1), then tighten mounting bolts. 3 Mounting bolt: 93.2 ± 5 Nm {9.5 ± 0.5 kgm}

14. Oil suction pipe Fit O-ring and install oil suction pipe (1).

95 SERIES

13-23

DISASSEMBLY AND ASSEMBLY

GENERAL ASSEMBLY

15. Oil pan Coat mounting face with gasket sealant, then install oil pan (1). 3 Mounting bolt: 31.9 ± 2.5 Nm {3.25 ± 0.25 kgm} 3 Drain plug: 58.9 ± 9.8 Nm {6.0 ± 1.0 kgm} 2 Mounting face: Gasket sealant (LG-7) a Coat the gasket sealant in a 1 mm wide film.

16. Fuel injection pump 1) Turn over cylinder block so that cylinder head is at top. 2) Fit O-ring, align match marks with idler gear, and install fuel injection pump assembly (5) together with fuel injection pump Ass’y. 3) Tighten mounting bolts (4). 4) Install bracket (3).

a Check that the match marks are aligned, then fit O-ring and install cover (6).

5) Install water hoses (2) for CSD and clamps (1). a Check the fuel injection timing, when fuel injection pump is installed.

13-24

95 SERIES

DISASSEMBLY AND ASSEMBLY

GENERAL ASSEMBLY

17. Cylinder head assembly 1) Assemble cylinder head assembly as follows. i) Using push tool G, install valve guide (6) in cylinder head (1).

ii) Coat stems of intake and exhaust valves and inside face of valve guide with engine oil. iii) Install valve (5). iv) Assemble valve spring (4) and spring seat (3).

v) Using spring pusher B, compress valve spring, and fit valve cotter (2) in valve stem groove. a After releasing the valve spring, tap the top of the valve stem with a plastic hammer to check that the cotter is completely fitted.

2) Install cylinder head assembly a Remove all carbon and dirt from the contact surfaces of the cylinder block and cylinder head. Remove all burrs and damage, and clean out all dirt from inside the cylinder block. i) Install cylinder head gasket. a Fit the gasket with the TOP mark facing up. ii) Raise cylinder head (1) then using 4 head bolts as guide, install cylinder head to cylinder block.

95 SERIES

13-25

DISASSEMBLY AND ASSEMBLY

GENERAL ASSEMBLY

3) Tightening cylinder head bolts Coat thread of cylinder head mounting bolts with molybdenum disulphide lubricant (LMP) and tighten as follows in order shown in diagram. 3 Cylinder head mounting bolt: (Tightening torque using plastic turning angle tightening) 1st step: 68.6 ± 9.8 Nm {7.0 ± 1.0 kgm} 2nd step: 107.8 ± 4.9 Nm {11.0 ± 0.5 kgm} 3rd step: Mark bolt head and cylinder head, th en t ur n b ol t 90 ( + 3 0 /0 ) ° to tighten a After tightening, make a punch mark on the bolt head to indicate the number of times the bolt has been tightened. a The bolt can be used a maximum of 5 times. Always replace any bolt that already has 5 punch marks.

18. Push rods Insert push rods (1) in tappet guides. a The same part is used for the intake and exhaust push rods. a If there is no abnormality in the push rod, install in the same position as before disassembly. 19. Rocker arm assembly 1) Install rocker arm assembly (2). 2) Check that ball of adjustment screw is fitted properly into socket of push rod, then tighten the nuts and bolts uniformly. 3 Mounting bolt of rocker arm bracket: 24.5 ± 5 Nm {2.5 ± 0.5 kgm} a If the valve spring tension pushes against the rocker arm, loosen the locknut and turn the adjustment screw back to prevent strain on the push rod.

13-26

95 SERIES

DISASSEMBLY AND ASSEMBLY

GENERAL ASSEMBLY

20. Adjusting valve clearance Adjust clearance between valve and rocker arm as follows. a Valve clearance (hot or cold) Unit: mm Intake valve

Exhaust valve

0.35

0.5

1) Rotate the crankshaft in the normal direction to align pointer (b) on the gear case cover with the 1.4 TOP mark (a) on crankshaft pulley (1). When rotating, check the movement of the intake valves of No. 4 cylinder. 2) When No. 1 cylinder is at compression top dead center, adjust the valve marked q. Then rotate the crankshaft 360° in the normal direction, and adjust the valves marked Q.

3) To adjust, insert tool H between rocker lever and valve stem and turn adjustment screw until clearance is a sliding fit. Then tighten locknut to hold adjustment screw in position. 3 Locknut: 44.1 ± 5 Nm {4.5 ± 0.5 kgm} 4) After adjusting No. 1 cylinder at compression top dead center, it is also possible to turn the crankshaft of each cylinder according to the firing order. a Firing order: 1 – 2 – 4 – 3 a After tightening the locknut, check the clearance again.

95 SERIES

13-27

DISASSEMBLY AND ASSEMBLY

GENERAL ASSEMBLY

21. Cylinder head cover 1) Fit O-ring to cylinder head cover. 2) Install cylinder head cover (3). 22. Nozzle holder 1) Install gasket (5). a Install the gasket with the blue mark facing up. 2) Install nozzle holder (2). 3 Nozzle holder: 68.7 ± 9.8 Nm {7 ± 1.0 kgm}

23. Spill tube Install spill tube (1). 3 Mounting bolt: 44.13 ± 4.9 Nm {4.5 ± 0.5 kgm}

24. Glow plug, glow lead 1) Install glow plug (2). 3 Glow plug: 17.2 ± 2.5 Nm {1.75 ± 0.25 kgm} 2) Install glow lead (1).

25. Intake manifold Install intake manifold (1). 2 Mounting surface: Gasket sealant (LG-7) a Coat the gasket sealant in a 1 mm wide film. 3 Mounting bolt: 40.2 ± 5.9 Nm {4.1 ± 0.6 kgm}

13-28

95 SERIES

DISASSEMBLY AND ASSEMBLY

GENERAL ASSEMBLY

26. Fuel injection pipe a Before installing the fuel injection pipe, blow compressed air through to clean it. 1) Install fuel injection pipe (2), then temporarily tighten sleeve nuts at both ends. 2) Align fuel injection pipes, then tighten clamps (1). 3) Fully tighten sleeve nuts of injection pipes. 3 Sleeve nut: 22.6 ± 2 Nm {2.3 ± 0.2 kgm}

27. Exhaust manifold Fit gasket and install exhaust manifold (1). 3 Mounting bolt: 44.7 ± 9.8 Nm {4.5 ± 1.0 kgm}

28. Turbocharger (S4D95LWE-5) 1) Install turbocharger (8), then tighten nuts (7). 2) Install joint bolts (5) and (6). 3) Install bolts (3) and clamps (4). 4) Tighten clamps (1) and (2).

29. Water pump Assemble O-ring on pilot, then fit gasket and install water pump (1).

95 SERIES

13-29

DISASSEMBLY AND ASSEMBLY

GENERAL ASSEMBLY

30. Oil filter, gauge guide 1) Install gauge guide (2), then secure with clamp. 2) Install oil filter (1).

31. Alternator Install alternator (1). 32. Fan pulley 1) Install fan pulley (3).

2) Fit belt (2) in pulley groove, then temporarily tighten adjustment plate (1). 3) Insert a bar or pipe between alternator and cylinder block, and raise alternator to outside to adjust fan belt tension. k Be careful not to get your fingers caught. a The belt should deflect 14 – 17 mm when pushed with a finger pressure of 58.8 N {6 kg} at a point midway between the alternator pulley and the crankshaft pulley. a After adjusting the bolt tension, tighten the bolts fully.

13-30

95 SERIES

DISASSEMBLY AND ASSEMBLY

GENERAL ASSEMBLY

33. Lowering engine 1) Sling engine assembly (2), disconnect engine from unit repair stand A, the lower engine on to a stable stand.

2) Remove bracket A1 from engine.

3) Fit O-ring and install starting motor (1).

95 SERIES

13-31

14 MAINTENANCE STANDARD Turbocharger ................................................................................................................................................ 14- 2 Cylinder head ............................................................................................................................................... 14- 6 Valve, valve guide......................................................................................................................................... 14- 7 Rocker arm shaft, push rod and tappet ........................................................................................................ 14- 8 Cylinder block ............................................................................................................................................... 14- 10 Cylinder ........................................................................................................................................................ 14- 10 Crankshaft .................................................................................................................................................... 14- 11 Camshaft ...................................................................................................................................................... 14- 12 Timing gear (Helical gear) ............................................................................................................................ 14- 14 Flywheel and flywheel housing..................................................................................................................... 14- 15 Piston, piston ring and piston pin.................................................................................................................. 14- 16 Connecting rod ............................................................................................................................................. 14- 18 Regulator valve............................................................................................................................................. 14- 20 Water pump and thermostat ......................................................................................................................... 14- 21

95 SERIES

14-1

MAINTENANCE STANDARD

TURBOCHARGER

Unit: mm

No.

item

Remedy

Standard

Repair limit

0.394 – 0.602

0.720

0.010 – 0.076

0.103

Target (Nm {kgm})

Range (Nm {kgm})

6.9 – 8.8 {0.7 – 0.9}

6.9 {0.7}

Radial play of rotor

End play of rotor

Tightening torque of clamp nut

14-2

Criteria

Repair or replace

Retighten

95 SERIES

MAINTENANCE STANDARD

95 SERIES

TURBOCHARGER

14-3

MAINTENANCE STANDARD

CYLINDER HEAD

CYLINDER HEAD 4D95LWE-5 S4D95LWE-5

*1: Nos. in Fig. indicate tightening order of cylinder head bolt.

14-4

95 SERIES

MAINTENANCE STANDARD

CYLINDER HEAD

Unit: mm

No.

Check item Distortion of cylinder head mounting surface

Tightening torque of cylinder head mounting bolt (Coat bolt threads and washers with molybdenum disulphide (LMP))

Criteria

Remedy

Standard

Repair limit

0 – 0.05

0 – 0.30

Order

Target Nm {kgm}

Range Nm {kgm}

1st step

68.6 {7}

58.8 – 78.4 {6 – 8}

107.8 {11}

102.9 – 112.7 {10.5 – 11.5}

Retighten 90º

90 +0

2nd step 3rd step

Repair by grinding or replace

Retighten, following order of above figure

+30º

Tightening bolt for plastic region rotation angle

Target Nm {kgm}

Range Nm {kgm}

Tightening torque of nozzle holder mounting bolt

44 {4.5}

39 – 49 {4 – 5}

Tightening torque of glow plug

17 {1.75}

15 – 20 {1.5 – 2.0}

Tightening torque of terminal nut

1.2 {0.125}

1.0 – 1.5 {0.1 – 0.15}

Tightening torque of head cover mounting bolt

8.8 {0.9}

7.8 – 9.8 {0.8 – 1.0}

95 SERIES

Retighten

14-5

MAINTENANCE STANDARD

VALVE, VALVE GUIDE

a Details may differ according to the machine model.

Unit: mm

No.

Check item

Criteria

Remedy

Tolerance 1

Sinking of valve

Repair limit

Intake

1.0 ± 0.25

2.00

Exhaust

0.9 ± 0.18

1.90

Thickness of valve head

15 ± 1.0

1.00

Standard 3

Tolerance

45º

± 15’

Shaft

Hole

Standard clearance

–0.035 –0.050

+0.015 +0.000

0.035 – 0.065

0.20

Exhaust 8

–0.050 –0.065

+0.015 +0.000

0.050 – 0.080

0.20

Intake

Correct valve

Judge contact surface or valve seat, condition with vacuum test or replace

Tolerance

Standard size 4

Replace

Repair limit

Valve seat angle

Clearance between valve guide and valve stem

Repair valve or valve seat

Clearance limit

Part No. (distinguishing feature)

Standard size

Repair limit

6204-41-4410 (Peach-color)

49.2

48.5

Replace either valve or valve guide or both

Free length of valve spring

Part No. (distinguishing feature)

Installed length

Standard load N {kg}

Load limit N {kg}

6204-41-4410 (Peach-color)

40.5

181 ± 8.8 {18.5 ± 0.9}

162 {16.5}

Replace

Installed load of valve spring

Out-of-square of valve spring

14-6

Driving-in height of valve guide

Repair limit: 18.5º Standard size

Tolerance

14.5

± 0.2

Correct

95 SERIES

MAINTENANCE STANDARD

ROCKER ARM SHAFT, PUSH ROD AND TAPPET

Unit: mm

No.

Check item

Criteria

Remedy

Standard

Tolerance

–0.000 –0.020

Replace rocker arm shaft

+0.030 +0.010

Replace rocker arm

Standard clearance

Clearance limit

0.010 – 0.050

0.12

Outside diameter of rocker arm shaft Inside diameter of rocker arm shaft hole 1 Clearance between rocker arm and rocker arm shaft

Replace rocker arm or rocker arm shaft

Bend of rocker arm shaft

Repair limit: 0.20 (Total indicated runout)

Replace rocker arm shaft

Bend of push rod

Repair limit: 0.30 (Total indicated runout)

Replace push rod

Tightening torque of adjustment nut of rocker arm

Valve clearance (at warm and cold)

Target Nm {kgm}

Range Nm {kgm}

44 {4.5}

39 – 49 {4 – 5}

Retighten

Valve

Standard

Tolerance

Intake

0.35

±0.02

Exhaust

0.50

±0.02

Standard

Tolerance

–0.015 –0.030

+0.018 –0.000

Replace cylinder block

Standard clearance

Clearance limit

0.015 – 0.048

0.12

Replace tappet or cylinder block

Outside diameter of tappet

Inside diameter of tappet hole

Clearance between tappet and tappet hole

95 SERIES

Adjust

Replace tappet

14-7

MAINTENANCE STANDARD

CYLINDER BLOCK

CYLINDER BLOCK 4D95LWE-5 S4D95LWE-5 (CAM JOURNAL NO.1, NO.2 AND NO.3 : WITH BUSHING)

Unit: mm

No. 1

Check item

Criteria

Distortion of cylinder head mounting surface

Standard

Repair limit

0 – 0.08

0.15

Standard

Tolerance

+0.019 +0.000

Inside diameter of main bearing hole 2

Roundness of main bearing hole

Repair limit: 0.005

Straightness of main bearing holes

Repair limit: 0.010 Standard size

14-8

Remedy

Inside diameter of main bearing

Inside diameter of cam bushing hole

STD

70.00

0.25 U.S.

69.75

Tolerance

Replace by grinding

Repair or replace cylinder block

Repair limit 70.20 69.95

+0.103 +0.043

0.50 U.S.

69.50

69.70

0.75 U.S.

69.25

69.45

1.00 U.S.

69.00

69.20

Standard

Tolerance

53.5

+0.030 +0.000

Replace main bearing

Repair or replace cylinder block

95 SERIES

MAINTENANCE STANDARD

No.

Check item

Criteria

Remedy

Journal

Standard

Tolerance

Repair limit

Inside diameter of cam bushing

No. 1

50.5

+0.030 –0.040

50.60

Inside diameter of cylinder block

No. 2 No. 3

50.5

+0.030 –0.040

50.60

CYLINDER BLOCK

Tightening torque of main bearing cap mounting bolts (Coat bolt threads and washers with engine oil)

95 SERIES

Replace

Order

Target Nm {kgm}

Range Nm {kgm}

1st step

113 {11.5}

108 – 118 {11 – 12}

2nd step

0 {0}

Loosen completely

3rd step

132 {13.5}

127 – 137 {13 – 14}

Press fit bushing

Retighten

14-9

MAINTENANCE STANDARD

CYLINDER

Unit: mm

No.

Check item

Criteria Standard size STD

0.25 OS

95.25

0.50 OS

95.50

Inside diameter

Remedy

Tolerance

95.15 +0.022 +0.000

Roundness of inside diameter

Repair limit: 0.020

Cylindricity of inside diameter

Repair limit: 0.020

Procedure for overhaul size

14-10

Repair limit

95.40 95.65

Correct with oversize, or install cylinder liner, or replace cylinder block

Measure inside diameter at position 40, 100, and 160 from top surface of cylinder block. Use largest value to determine overhaul (When size. carrying out (1) If cylinder bore is less than 95.15: Select 0.25 oversize piston overhaul) +0.022 and machine cylinder bore in cylinder block to 95.25 +0 . Rank cylinder (2) If cylinder bore is between 95.16 and 95.40: Select 0.50 overbore at top size piston and machine cylinder bore in cylinder block to face of 95.50. +0.022 +0 cylinder block (3) If cylinder bore is more than 95.40: Carry out stepped machinand correct ing of cylinder block and insert cylinder liner. For details of the mark (S or L) method for machining the cylinder block and selecting the cylinder liner, see REPAIR AND REPLACEMENT OF PARTS.

95 SERIES

MAINTENANCE STANDARD

CRANKSHAFT

Unit: mm

No.

Check item

End play

Criteria Standard

Repair limit

0.131 – 0.351

0.40

Standard size

Outside diameter of main journal 2

70.00

69.86

69.75

69.61

Bend of crankshaft

95 SERIES

+0.015 +0.000

0.50 U.S.

69.50

0.75 U.S.

69.25

69.11

1.00 U.S.

69.00

68.86

69.36

Repair by using under size bearing or replace

Repair limit: 0.020 Standard clearance

Clearance limit

0.043 – 0.103

0.25

STD

57.00

0.25 U.S.

56.75

Tolerance

Replace main bearing

Repair limit 56.91 56.66

+0.015 +0.000

0.50 U.S.

56.50

0.75 U.S.

56.25

56.16

1.00 U.S.

56.00

55.91

Roundness of crankpin journal Clearance of crankpin journal

Repair limit

STD

Standard size

Outside diameter of crankpin journal

Tolerance

Repair by using over size thrust bearing or replace

0.25 U.S.

Roundness of main journal Clearance of main journal

Remedy

56.41

Repair by using under size bearing or replace

Repair limit: 0.020 Standard clearance

Clearance limit

0.029 – 0.089

0.22

Repair limit: 0.09 (Total indicated runout)

Replace connecting rod bearing Repair by using under size bearing or replace

14-11

MAINTENANCE STANDARD

CAMSHAFT

CAMSHAFT 4D95LWE-5 S4D95LWE-5 (BUSHING INSTALLED TO JOURNAL NO. 1, NO.2 AND NO. 3)

Unit: mm

No.

Check item

Criteria

Standard size

Repair limit

0.150 – 0.350

0.5

Replace thrust plate

End play

Journal 2

Remedy

Outside diameter of camshaft bearing journal

No.1 No.2 No.3

Curvature of camshaft

Standard size

50.5

Tolerance Shaft

Hole

Standard Clearclearance ance limit

–0.080 –0.110

+0.030 –0.040

0.040 – 0.140

Replace bushing 0.25

Repair limit: 0.03 (Total deflection of indicator) Standard size

Tolerance

Repair limit Replace

Height of camshaft

Intake

43.24

Exhaust

43.44

42.7 ±0.10

14-12

42.9

95 SERIES

MAINTENANCE STANDARD

No.

CAMSHAFT

Check item

Criteria Valve position

Crankshaft angle

Remedy

When testing (Crankshaft angle when valve has gone down 1 mm) Standard

Valve timing

Tolerance

Intake open

Before TDC

9º

After TDC

8º

Intake closed

After BDC

40º

After BDC

23.5º

Exhaust open

Before BDC

60º

Before BDC

45º

Exhaust closed

After TDC

12º

Before TDC

9º

±3º

95 SERIES

Check for curvature or wear of valve, camshaft, push rod. Correct or replace

14-13

MAINTENANCE STANDARD

TIMING GEAR (HELICAL GEAR)

TIMING GEAR (HELICAL GEAR) 4D95LWE-5 S4D95LWE-5

Unit: mm

No.

Check item

Backlash of each gear

Criteria

Remedy

Measuring point

Gears

Standard

Crankshaft gear and idler gear

0.08 – 0.19

Idler gear and camshaft gear

0.08 – 0.19

Idler gear and fuel injection pump gear

0.07 – 0.29

Camshaft gear and oil pump gear

0.07 – 0.29

Repair limit

0.04

Clearance between idler gear bushing and shaft

Standard size 45

Tolerance Shaft

Hole

Standard clearance

Clearance limit

–0.000 –0.016

+0.083 +0.018

0.018 – 0.099

0.15

Standard

Repair limit

0.08 – 0.14

0.25

End play of idler gear

14-14

Replace bushing or gear

Replace idler shaft, thrust plate or gear

95 SERIES

MAINTENANCE STANDARD

FLYWHEEL AND FLYWHEEL HOUSING

Unit: mm

No.

Check item

Criteria

Remedy

Face runout of flywheel housing

Repair limit: 0.30

Radial runout of flywheel housing

Repair limit: 0.30

Tightening torque of flywheel housing mounting bolts

Radial runout of flywheel housing

Repair limit: 0.35

Face runout of flywheel

Repair limit: 0.30

Tightening torque of flywheel mounting bolts (Coat bolt threads and washers with engine oil)

95 SERIES

Repair by reassembling

58.8 ± 73.5 Nm {6.0 ± 7.5 kgm}

Retighten

Repair by reassembling

Order

Target Nm {kgm}

Range Nm {kgm}

1st step

883 {9}

58.8 – 118 {6 – 12}

2nd step

191 {19.5}

186 – 196 {19 – 20}

Retighten

14-15

MAINTENANCE STANDARD

PISTON, PISTON RING AND PISTON PIN

PISTON, PISTON RING AND PISTON PIN 4D95LWE-5

Unit: mm

No.

Check item

Criteria

Outside diameter of piston (at right angle to boss)

Standard size

Repair limit

STD

94.920

94.905

0.25 O.S.

95.170

95.155

0.50 O.S.

95.420

95.405

Standard clearance

Clearance limit

Replace piston

No.

Measuring point

Top ring

0.30 – 0.45

2.0

Second ring

0.40 – 0.50

2.0

Oil ring

0.25 – 0.50

1.5

No.

Measuring Standard size point

2 3

5 Clearance between piston ring groove and piston ring

Replace piston ring or liner

Piston ring gap

Remedy

Clearance between piston and piston pin

Ring

Piston

Standard Clearance clearance limit

Top ring

2.2

–0.01 –0.03

+0.07 +0.05

0.06 – 0.10

0.15

Second ring

–0.01 –0.03

+0.04 +0.02

0.03 – 0.07

0.20

Oil ring

–0.01 –0.03

+0.04 +0.02

0.03 – 0.07

0.15

Standard size 30

14-16

Tolerance

Tolerance Shaft

Hole

Standard clearance

Clearance limit

–0.000 –0.006

+0.012 +0.004

0.004 – 0.018

0.05

Replace piston ring or piston

Replace piston or piston pin

95 SERIES

MAINTENANCE STANDARD

PISTON, PISTON RING AND PISTON PIN

S4D95LWE-5

Unit: mm

No.

Check item

Criteria

Outside diameter of piston (at right angle to boss)

Standard size

Repair limit

STD

94.920

94.905

0.25 O.S.

95.170

95.155

0.50 O.S.

95.420

95.405

Standard clearance

Clearance limit

Replace piston

No.

Measuring point

Top ring

0.30 – 0.45

2.0

Second ring

0.40 – 0.50

2.0

Oil ring

0.25 – 0.50

1.5

No.

Measuring point

2 3

Standard size

5 Clearance between piston ring groove and piston ring

Replace piston ring or liner

Piston ring gap

Remedy

Clearance between piston and piston pin

Ring

Piston

Standard Clearance clearance limit

Top ring

2.2

–0.01 –0.03

+0.07 +0.05

0.06 – 0.10

0.15

Second ring

–0.01 –0.03

+0.04 +0.02

0.03 – 0.07

0.20

Oil ring

–0.01 –0.03

+0.04 +0.02

0.03 – 0.07

0.15

Standard size 30

95 SERIES

Tolerance

Tolerance Shaft

Hole

Standard clearance

–0.000 –0.006

+0.012 +0.004

0.004 – 0.018

Clearance limit 0.05

Replace piston ring or piston

Replace piston or piston pin

14-17

MAINTENANCE STANDARD

CONNECTING ROD

Unit: mm

No.

Check item

Clearance between connecting rod bushing and piston pin (carry out reaming after press fitting)

Criteria Tolerance

Standard size 30

Inside diameter of connecting rod bushing hole

Shaft

Hole

Standard clearance

Clearance limit

–0.000 –0.006

+0.033 +0.020

0.020 – 0.039

0.10

Standard

Tolerance

+0.025 +0.000 Standard size

Inside diameter of connecting rod bearing

Inside diameter of connecting rod bearing hole

Tolerance

Repair limit

57.00

57.20

0.25 U.S.

56.75

56.95

0.50 U.S.

56.50

0.75 U.S.

56.25

56.45

1.00 U.S.

56.00

56.20

+0.095 +0.045

56.70

Standard

Tolerance

+0.025 +0.000 Standard

Repair limit

Bend a

Max. 0.20

0.25

Twist b

Max. 0.30

0.35

Dimension c

167

—

Dimension d

167

—

Order

Target Nm {kgm}

Range Nm {kgm}

1st step

39 {4}

37 – 41 {3.8 – 4.2}

Retighten with 90º

+30º 90 +0

2nd step

Replace bushing (semi-finished part supplied as replacement part)

Replace connecting rod

STD

Bend and twist of connecting rod

Tightening torque of connecting rod cap mounting bolts (Coat bolt threads and washers with engine oil)

Remedy

Replace connecting rod bearing

Replace connecting rod

Retighten

Tightening bolt for plastic region rotation angle

14-18

95 SERIES

MAINTENANCE STANDARD

CONNECTING ROD

Unit: mm

No.

Check item

Criteria Standard size

Axial clearance of pump gear 21

Tolerance Gear width

Body depth

–0.000 –0.016

+0.070 –0.030

Remedy Standard clear- Clearance limit ance (End play) (End play) 0.030 – 0.086

0.10 Clearance limit 0.13

Replace gear Standard size 2

Radial clearance of pump gear 38

Interference between pump drive gear and drive shaft

Tolerance Gear width

Body O.D.

Standard clearance

+0.115 +0.065

+0.245 +0.205

0.045 – 0.090

Tolerance Shaft

Hole

Standard clearance Clearance or or interference interference limit

–0.024 –0.042

–0.065 –0.086

0.025 – 0.061

—

Standard size

Replace

Clearance between drive shaft and cover

–0.024 –0.042

+0.018 +0.000

0.024 – 0.060

—

Replace bushing

Interference between pump gear and drive shaft

–0.024 –0.042

–0.065 –0.086

0.025 – 0.061

—

Replace

Clearance between drive shaft and bushing

–0.024 –0.042

+0.048 +0.004

0.028 –

—

Replace bushing

Clearance between driven shaft and cylinder block

–0.064 +0.046

+0.018 +0.000

0.028 – 0.064

—

Replace cylinder block

Clearance between driven shaft and gear

+0.110 –0.125

–0.065 –0.086

0.024 – 0.060

—

Replace shaft or gear

Clearance between drive shaft bushing hole and cylinder block

+0.087 +0.060

+0.018 +0.000

0.042 – 0.087

—

Replace cylinder block

95 SERIES

0.09

14-19

MAINTENANCE STANDARD

REGULATOR VALVE

Unit: mm

No.

Check item

Clearance between valve and body

Criteria Tolerance

Standard size 11

Remedy

Shaft

Hole

Standard clearance

–0.050 –0.077

+0.020 –0.020

0.030 – 0.097

Clearance limit

• Free length Standard size: 30.4 • Installed load

Replace

Standard 2

Regulator valve spring

Regulator valve set pressure

14-20

Repair limit

Installation length

Standard load N {kg}

Load limit N {kg}

27.8

19.8 N {2.02 kg}

18.8 N {1.92 kg}

Standard: 0.6 ± 0.05 MPa {6.0 ± 0.5 kg/cm2}

Repair or replace spring

95 SERIES

MAINTENANCE STANDARD

WATER PUMP AND THERMOSTAT

Unit: mm

No. 1

Check item

Criteria

Clearance of impeller body

Remedy

Standard clearance: 0.3 – 2.0 Tolerance Standard size

Interference between shaft and fan pulley boss

Standard interference

Shaft

Hole

0 –0.013

–0.066 –0.082

0.053 – 0.082

Interference between shaft and body

0 –0.013

–0.025 –0.046

0.012 – 0.046

Interference between shaft and impeller

0 –0.013

–0.035 –0.062

0.022 – 0.062

Curvature of shaft

Wear of seal ring of water seal

Thermostat

95 SERIES

Replace

Repair limit: Runout at face (B): 0.1 Repair limit: Dimension (A): 0 • Cranking temperature: 82 ± 2ºC (Fully open: Shall open fully when immersed in hot water bath at temperature between 95ºC and 77ºC for 4 – 5 minutes) • Fully open temperature: 95ºC • Fully open life: Min. 8 (When immersed in hot water bath at 95ºC for 4 – 5 minutes)

14-21

15 REPAIR AND REPLACEMENT OF PARTS CYLINDER HEAD SECTION Grinding cylinder head mounting surface ..................................................................................................... 15- 2 Replacing valve guide .................................................................................................................................. 15- 3 Grinding valve............................................................................................................................................... 15- 4 CYLINDER BLOCK SECTION Replacing camshaft bushing ........................................................................................................................ 15- 5 Replacing crankshaft gear ............................................................................................................................ 15- 7 Testing and adjusting fuel injection timing .................................................................................................... 15- 8 Replacing flywheel ring gear ........................................................................................................................ 15- 9 Procedure for pressure test .......................................................................................................................... 15- 10 Cylinder liner (special restoration part) ......................................................................................................... 15- 11 Machining drawing for cylinder block bore ................................................................................................... 15- 12 Additional machining of cam journal............................................................................................................. 15- 13 Grinding crankshaft ...................................................................................................................................... 15- 14 Replacing connecting rod small end bushing ............................................................................................... 15- 15

95 SERIES

15-1

REPAIR AND REPLACEMENT OF PARTS

GRINDING CYLINDER HEAD MOUNTING SURFACE

GRINDING CYLINDER HEAD MOUNTING SURFACE 1. Grinding Grind the bottom surface of the cylinder head with a surface grinding machine to remove deformation or corrosion. Do not exceed the repair limit of cylinder head height H. After grinding, make an R mark at the rear on the left side (intake side) of the cylinder head. a Standard dimension of cylinder head height –0 H: 90 –0.2 mm Repair limit: 89.5 mm a Amount to remove per grinding: 0.10 – 0.15 mm a Surface roughness of grinding surface: Within 6S a Flatness (deformation): Within 0.05 mm a Grinding limit: 0.3 mm 2. Check after grinding Check that the insertion depth of the valve is within the standard value. a Insertion depth of valve: Intake side: 1.0 ± 0.25 mm Exhaust side: 0.9 ± 0.18 mm a Check the protrusion of the swirl chamber insert (port plug) from the bottom of the cylinder head and check that it is within the standard value. a Protrusion: 0 – 0.08 mm

15-2

95 SERIES

REPAIR AND REPLACEMENT OF PARTS

REPLACING VALVE GUIDE

REPLACING VALVE GUIDE Special tools No.

Part No.

Part Name

Q'ty

795-100-4710

Valve guide remover

795-100-4720

Valve guide driver

1. Removal of valve guide Insert tool A from the top surface of the cylinder head, put it in contact with the valve guide, then hit with a hammer to remove the valve guide. 2. Press fitting valve guide 1) Press fit the valve guide until the tip of tool B contacts the cylinder head. a After press fitting, insert the valve, and if the valve does not enter smoothly, machine the hole with a reamer +0.015 (ø8 +0 mm). 2) Measure the protrusion of the valve guide and check that it is within the standard range. a Valve guide protrusion Tolerance: 14.5 ± 0.2 mm

95 SERIES

15-3

REPAIR AND REPLACEMENT OF PARTS

GRINDING VALVE

GRINDING VALVE Special tool No.

Part No.

Part Name

Q'ty

Commercially available

Valve refacer

1. Grinding seat face After using tool A to adjust the valve seat angle, grind the seat face. a For details of the angle of the valve seat, see the Maintenance Standard Table. 2. Checking after grinding Measure the thickness of the valve head, insertion depth of the valve and the contact of the valve seat face to check that they are within the standard range. a Thickness of valve head: 1.40 – 1.60 mm a Insertion depth of valve Intake side: 1.0 ± 0.25 mm Exhaust side: 0.9 ± 0.18 mm a Contact width of valve Standard Intake valve: 2.0 mm Exhaust valve: 2.0 mm a For details of handling the valve refacer, see the operation manual.

15-4

95 SERIES

REPAIR AND REPLACEMENT OF PARTS

REPLACING CAMSHAFT BUSHING

REPLACING CAMSHAFT BUSHING Special tools No.

Part No.

Part Name

Q'ty

795-215-1101

Push tool (KIT)

795-215-1110

Push bar

795-215-1120

Push tool

795-215-1140

Collar

795-215-1150

Guide

1. Removing front and rear bushings As shown in the diagram, assemble push tool (2), collar (3), and push bar (1) of push tools A, then hit the push bar to knock bushing (6) out from cylinder block (5).

2. Removing center bushing 1) Assemble push bar (1), push tool (2), collar (3), and guide (4) of push tool A, then hit the push bar to knock bushing (6) out from cylinder block (5).

95 SERIES

15-5

REPAIR AND REPLACEMENT OF PARTS

REPLACING CAMSHAFT BUSHING

a Cam bushing assembly drawing 2) After removing the bushing, remove any burrs or dirt from the mounting hole of the bushing.

3. Press fitting center bushings Assemble bushing (6) to tool A and press fit the bushing until the oil hole in cylinder block (5) is aligned with the oil hole in the bushing.

4. Press fitting front and rear bushings Assemble bushing (6) to tool A, and press fit the bushing until the oil hole in cylinder block (5) is aligned with the oil hole of the bushing.

5. After press fitting bushings 1) Using inside gauge [1], measure the inside diameter of the bushing. 2) Check the clearance between the bushing and shaft, and if the clearance is not within the specified range, or the shaft does not pass through smoothly, correct the inside diameter of the bushing with a reamer. • When correcting the inside diameter of the bushing with a reamer, clean all chips from the oil hole and oil groove. a Inside diameter of cam bushing: ø50.5 +0.030 –0.040 mm a Clearance of camshaft journal: 0.030 – 0.130 mm

15-6

95 SERIES

REPAIR AND REPLACEMENT OF PARTS

REPLACING CRANKSHAFT GEAR

REPLACING CRANKSHAFT GEAR 1. Removal of gear Remove the gear with a gear puller. 2. Press fitting gear 1) Check the gear mounting surface, key groove, and flange surface, and if there are any scratches, correct them with an oilstone. 2) Knock the key into the key groove of the shaft. 3) Heat the gear for the specified time at the specified shrink-fitting temperature. a Crankshaft gear shrink-fitting temperature: 230 – 250ºC Heating time: Min. 30 minutes 4) Put the timing mark on the outside, then use a hitting tool to press fit until the side face of the gear is in tight contact with the shaft flange. a Knock in quickly before the gear becomes cool.

95 SERIES

15-7

REPAIR AND REPLACEMENT OF PARTS

TESTING AND ADJUSTING FUEL INJECTION TIMING

TESTING AND ADJUSTING FUEL INJECTION TIMING 1. When using only shrink fitting 1) Check the gear mounting surface, key groove, and flange surface, and if there are any scratches, correct them with an oilstone. 2) Knock the key into the key groove of the shaft. 3) Heat the gear for the specified time at the specified shrink-fitting temperature. a Cam gear shrink-fitting temperature: 250 – 270ºC Heating time: Min. 30 minutes 2. When combining shrink fitting and tightening with bolt 1) Press fit with the bearing installed to the camshaft. Put the inner race of the bearing in contact with the shoulder of the No. 1 journal. 2) Knock the key (6206-41-1380) into the camshaft. When doing this, check that the key is below the surface of the tip of the camshaft. (See diagram on right) 3) Heat the cam gear in a furnace at 220 – 240ºC for approx. 35 minutes. 4) When press fitting the cam gear to the camshaft, use a press to apply a force of approx. 29.4 kN {3 tons} to the outer shoulder of the gear so that the bearing inner race is pressed against the end of the inside of the cam gear. When the cam gear has cooled to room temperature, push with a press to press fit it fully. 5) Insert the bolts in the plates and coat the thread with LT-2, then tighten to the camshaft. a After tightening to the specified torque, loosen the bolts, then tighten again to the specified torque. 3 Bolt: 98 – 123.5 Nm {10 – 12.5 kgm} After press fitting, tighten the bolts fully within 2 minutes, and be sure that the cam gear temperature has not gone down.

15-8

95 SERIES

REPAIR AND REPLACEMENT OF PARTS

REPLACING FLYWHEEL RING GEAR

REPLACING FLYWHEEL RING GEAR k Be

careful not to let the flywheel fall and injure you.

1. Removal of ring gear 1) Prepare a support for the flywheel, and set on the support with the ring gear surface facing down. 2) Heat the area around the ring gear with a torch lamp, then hit it with a hammer to remove it. 2. Press fitting ring gear 1) Check the ring gear mounting surface, and if there are any scratches, correct them with an oilstone. 2) Heat the ring gear for the specified time at the specified shrink-fitting temperature. a Ring gear shrink-fitting temperature: Max. 200ºC Heating time: Min. 45 minutes 3) Set the chamfered face of the ring gear facing the flywheel, and press fit until the side face of the gear is in tight contact with the flywheel.

95 SERIES

15-9

REPAIR AND REPLACEMENT OF PARTS

PROCEDURE FOR PRESSURE TEST

PROCEDURE FOR PRESSURE TEST •

When corrections have been made around the cylinder head, test the pressure as follows.

Special tools No.

Part No.

Part Name

Q'ty

790-513-4200

Coolant test kit

79A-471-1050

Pump assembly

1. Water pressure test 1) Tighten the nozzle holder assembly to the specified torque. 2) Assemble tool A and tool B, and connect the hose to flange (1). 3) Apply water pressure 0.25 – 0.6 MPa {2.5 – 6.0 kg/cm 2 } for approx. 10 minutes, and check that there is no leakage from around the head. a When carrying out this test, heat the whole cylinder head and carry out the test with hot water (82 – 93ºC). 2. Air pressure test 1) Tighten the nozzle holder assembly to the specified torque. 2) Connect the compressor hose to flange (1). 3) Put the head in the container of water, apply air pressure 0.2 MPa {2.0 kg/cm 2 } for approx. 30 seconds, and check that there is no leakage in the water. a If the above test shows any cracks in the nozzle holder or around the plate plugs, replace the cylinder head. a If cracks are found in any other places, weld to repair.

15-10

95 SERIES

REPAIR AND REPLACEMENT OF PARTS

CYLINDER LINER

CYLINDER LINER (SPECIAL RESTORATION PART) Cylinder liner • The 95 Series engine has a liner-less cylinder, so if the cylinder bore exceeds 95.40 mm because of wear, the cylinder is bored, and this cylinder liner is used to restore the cylinder. Selection of liner There are two sizes of cylinder liner: A and B. After machining the cylinder bore, select the size of liner to match the bore.

•

Outside diameter of cylinder liner Unit: mm

Category mark Part No.

Measurement location

Letter

line

6207-21-2110

+0.020 +0.005

+0.025 –0.010

+0.025 –0.020

+0.0125 +0.0000

6207-21-2120

+0.035 +0.020

+0.040 +0.005

+0.040 –0.005

+0.0250 +0.0125

95 SERIES

[a]

[b]

[c]

[Remark] Machined dimension of cylinder

15-11

REPAIR AND REPLACEMENT OF PARTS

MACHINING DRAWING FOR CYLINDER BLOCK BORE

MACHINING DRAWING FOR CYLINDER BLOCK BORE •

Honing

15-12

95 SERIES

REPAIR AND REPLACEMENT OF PARTS

ADDITIONAL MACHINING OF CAM JOURNAL

ADDITIONAL MACHINING OF CAM JOURNAL Carry out additional machining of the cam journal, and install a cam bushing (Part No.: 6206-21-1420) to correct the damage. 1. To carry out the additional machining, disassemble to make the cylinder block into an individual part. a To clean out the metal particles after machining, remove the taper plug from the oil hole, the µ-plug, and the oil pressure caution switch. Remove parts (a) – (e) in the diagram.

2. Center with an undamaged cam journal and carry out additional machining. (See Cross-sectional diagram (1)) Inside diameter ø after machining: 53.5 +0.03 mm +0 (Surface roughness: Max. 12.5 S) 3. Align the oil hole in the cam bushing with the oil hole in the cylinder block, and press fit. After press fitting, insert a ø 3.5 check bar through the oil hole in the main journal and check that it presses through the oil hole. (Diameter of bushing oil hole: ø 4) 4. After press fitting, check the inside diameter of the bushing. (See Cross-sectional diagram (2)) Inside diameter of bushing: ø 50.5 +0.02 –0.05 mm 5. Clean thoroughly and check that there are no metal particles remaining in the oil hole. 6. To check the alignment of the journal at three places, insert the cam shaft and check that it rotates smoothly by hand. 7. Remove the cam shaft, then install the taper plug for the oil hole, the µ-plug (replace with a new part), and the oil pressure caution switch to the cylinder block.

95 SERIES

15-13

REPAIR AND REPLACEMENT OF PARTS

GRINDING CRANKSHAFT

GRINDING CRANKSHAFT Applicable crankshaft • It is possible to correct by grinding and rebuild so that undersize bearings can be used only with crankshafts which have received induction hardening. This method of repair may not be used for crankshafts that have received tufftride treatment. (*1) • It is possible to distinguish these two types of crankshaft from the engine serial number (*2), but check the crankshaft as follows to ensure that there is no mistake.

(*1) With tufftride treatment, the hardened layer is thin, so if additional grinding is carried out, the hardened layer will be removed and it will be impossible to ensure the strength and wear resistance. (*2) The part number does not change when there is change in the surface treatment of the crankshaft, but as shown above, the crankshaft pin bearing is changed at the same time.

15-14

95 SERIES

REPAIR AND REPLACEMENT OF PARTS

REPLACING CONNECTING ROD SMALL END BUSHING

REPLACING CONNECTING ROD SMALL END BUSHING Special tools No. A

Part No.

Part Name

Q'ty

795-233-1100 Push tool (KIT)

795-233-1110 Push tool

2 795-233-1120 Push tool

3 795-233-1130 Nut

4 795-233-1140 Block

1 B

—

Jig for pulling out bushing

—

Jig for press fitting bushing

a If the special tools are not available, prepare substitutive jigs C and D. 1. Removal of connecting rod bushing 1) Set connecting rod (2) to tool B3. 2) Using tools B1 and B3, remove connecting rod bushing (1) with press. a After removing the bushing, remove any burrs or flashes, and clean the mounting hole of the bushing.

2. Press fitting connecting rod bushing 1) Set connecting rod (2) to tool B3. 2) Assemble connecting rod bushing (1) in tool B1, set tool B2 in position, then secure with tool B4 so that it does not move. a Align the oil hole of the connecting rod bushing with the oil hole of the connecting rod. 3) Push tool B1 with press, and press fit connecting rod bushing (1). •

The bushing is supplied as a semi-finished product, so the inside diameter is too small and the piston pin will not go in. After press fitting the bushing, machine the inside diameter of the bushing with a reamer or honing machine in accordance with the maintenance standard. a After machining, clean all the metal particles from the oil hole and oil groove.

95 SERIES

15-15