KOMATSU ENGINE

MODEL: S6D95L-1.

SERIE 95 – SPECIAL EDITION.

SPECIFICATIONS:

MONOBLOCK:
1.- Adjustment of the main bearing caps of the crankshaft:
1st stage: 11.5 Kgm (11-12 Kgm range)
2nd stage: 0 loosen completely
3rd stage: 13.5 Kgm (13-14 Kgm range)
4th stage: 13.5 Kgm (13-14 Kgm range)

2.- Axial clearance of the crankshaft: 0.13 - 0.35 mm

3.- Roundness of the cylinder: repair limit: 0.02 mm

4.- Cylindricity of the cylinder: repair limit: 0.02 mm

5.- Roundness of the main bearing hole: limit: 0.005 mm

6.- Straightness of the bench tunnel: limit: 0.010 mm

7.- Crankshaft twist: limit: 0.09 m.m total.

8.- Main stump clearance: oil gap:

Std: 0.043 – 0.103 mm limit: 0.25 mm

9.- Distortion of the crankshaft surface:

Std: 0 – 0.08 mm limit: 0.15 mm.

10.- Inner diameter of the main bearing hole:

Std: 74 mm limit: + 0.019 mm

CRANKS:
1.- Crank adjustment:
1st stage: 4.0 Kg.m (4.0-4.2 Kg.m range)
2nd stage: 4.0 Kg.m (4.0-4.2 Kg.m range)
3rd stage: 90º or more rotation (90º - 120º range)
Mark the bolt with a punch, with 5 marks on the head, change the
connecting rod bolts.

2.- Lateral clearance of the connecting rod: 0.20 – 0.40 mm

3.- Bending and twisting of the connecting rod:

Doubling: 0.25 mm tolerance.
Sprain: 0.35 mm tolerance.
4.- Oil clearance between the journal and the connecting rod:
Std: 0.029 – 0.089 mm limit:
0.22 mm

5.- Clearance between piston pin and connecting rod bushing:

Std: 0.020 – 0.039 mm limit: 0.10 mm

CAMSHAFT:
1.- Axial clearance of the camshaft:
Std: 0.150 – 0.350 mm limit: 0.50 mm

2.- Oil clearance between camshaft and bushings:

Std: 0.030 – 0.130 mm limit: 0.25 mm

3.- Twisting of the camshaft: limit: 0.03 m.m total.

STEERING WHEEL:
1.- Adjustment of steering wheel bolts:
1st stage: 11 Kg.m (10-12 Kg.m range)
2nd stage: 19.5 Kg.m (19-20 Kg.m range)
3rd stage: 19.5 Kg.m (19-20 Kg.m range)

DISTRIBUTION: INTERMEDIATE GEAR:

1.- Clearance between the horn and the axis of the intermediate gear:
Std: 0.015 - 0.050 mm limit: 0.10 mm

2.- Axial clearance of the intermediate gear:

Std: 0.03 – 0.09 m.m 0.20
limit:mm

CRANKSHAFT PULLEY:
1.- Adjustment of the crankshaft pulley: 38.0 +/- 3.0 Kg.m

PISTON RINGS:
1.- Clearance between the tips of the rings:
1st: Std: 0.28 – 0.38 mm limit: 2.0 mm
2nd: Std: 0.30 - 0.45 mm limit: 2.0 mm
3rd: Std: 0.25 – 0.45 mm limit: 2.0 m.m

2.- Clearance between rings and grooves:

1st: Std: 0.04 – 0.08 mm limit: 0.20 mm
2nd: Std: 0.04 – 0.08 m.m limit: 0.20 mm
3rd: Std: 0.03 – 0.08 mm limit: 0.15 mm

3.- Clearance between pin and piston:

Std: 0.004 – 0.018 mm limit: 0.05 mm
* CULATA:
1.- Head bolt adjustment:

O = pin.

O23 19O O15 11007 3O O2 60 O10 140 O18 O22

center
O25 O17 O9 O1 O8 O16 O24

O21 O13 O5 O4 O12 O20

Note:
The angular adjustment bolts have the following measurements and characteristics:
Screw length: 55 mm
Stem length: 120 mm
The head is striped with a circle in the center.

The bolts for torque adjustment have the following measurements and
characteristics:
Thread length: 28 mm
Rod length: 120 mm
The head is striped and has a symbol in the center.

ADJUSTMENT PROCEDURE:
1st stage: 7 Kg.m (6-8 Kg.m range)
2nd stage: 11 Kg.m (10.5-11.5 Kg.m range)
3rd stage: 11 Kg.m (10.5-11.5 Kg.m range)
4th stage: 90º + rotation (90º - 120º range)

After adjusting, place a mark with a punch on the head of the bolt.
05 brands change the cylinder head bolts.

2.- Height of valve guide insertion:

Std: 14.5 m.m tolerancia: +/- 0.2 mm

3.- Surface distortion:

Std: 0 – 0.05 mm ( 0 – 0.08 m.m )
Limit: 0.30 mm (0.15 m.m)

4.- Injector protrusion:

Std: 3.12 +/- 0.28 mm
limit: 2.7 – 3.5 mm

5.- Adjustment of the injector bolt: 4.5 +/- 0.5 Kg.m

VALVES:
1.- Valve sinking, with respect to the surface of the cylinder head:
Tolerance: 0 +/- 0.18 mm
Repair limit: 1.00 mm
2.- Thickness of the valve head:
Tolerance: 1.40 – 1.60 mm
Repair limit: 1.00 m.m

3.- Valve seat angle:

Std: 45º Tolerance: +/- 15º

4.- Clearance between guide and valve:

Std: Admission: 0.035 – 0.065 mmlimit: 0.20 mm
Escape: 0.050 – 0.080 limit:
mm 0.20 mm

5.- Free length of the valve spring:

Peach color: Std: 49.2 m.m limit: 48.5 mm
Red color: Std: 56.0 m.m limit: 55.0 mm

6.- Valve adjustment:

Admisión: 0.35 m.m (0.014")
Escape: 0.50 mm (0.020”)

SEQUENCE - PROCEDURE
O = Cylinder No. 1 in the compression PMS.
X = Cylinder No. 1 in the escape PMS.

3 CYLINDER ENGINE:

No. Cil: 1 2 3
-----------------------------------------------------------------

Adm. O O X
Esc. O X O

4-CYLINDER ENGINE:

Cyl No: 1 2 3 4

Adm. O X O X
Esc. O O X X

6 CYLINDER ENGINE:

No. Cil: 1 2 3 4 5 6

Adm. O O X O X X
Esc. O X O X O X

The TOP mark of the damper or crankshaft pulley must be aligned with the notch or
pointer in the distribution box.

7.- Order of ignition:

3-cylinder engine: 1-3-2 240º
 4-cylinder engine: 1-2-4-3 = 180º
6-cylinder engine: 1-5-3-6-2-4 = 120º

ROCKER ARMS:
1.- Diameter of the rocker shaft:
Std: 19 mm tolerance +/- 0.020 mm

2.- Inner diameter of the hole:

Std: 19 mm tolerance + 0.030 - 0.010 m.m

3.- Clearance between shaft and rocker arm:

Std: 0.010 – 0.050 mm limit: 0.12 mm

4.- Axial twisting: limit: 0.20 mm

5.- External diameter of the diver:

Std: 16 mm tolerance + 0.015 - 0.030 mm

6.- Inner diameter of the hole for the diver:

Standard: 16 mm tolerance + 0.018 mm

7.- Clearance between the diver and the hole:

Std: 0.015 – 0.090 mm limit: 0.12 m.m

WATER PUMP:
1.- Clearance between impeller and body: (integrated bearing)
Std: 0.30 – 1.00 m.m

2.- Clearance between the impeller and the body: (separate bearing)
Std: 0.77 – 1.92 mm

OIL PUMP:
1.- Pressure valve:
Clearance between valve and body: Std: 0.030 – 0.097 mm
Free length of valve spring:
Std: 33.1 mm for the models: 3D95S, 4D95L, 4D95S.
Std: 30.1 m.m for everyone except the previous ones.

TURBO:
1.- Radial clearance of the axis:
Std: 0.075 – 0.150 mm limit: 0.18 mm

2.- Axial play of the shaft:

Std: 0.025 – 0.075 mm limit: 0.10 mm

FUEL INJECTION SYSTEM:

1.- Synchronization of the injection pump:

A.- WORK METHOD:

Procedure:
1.- Rotate the engine crankshaft until the mark (1-6) on the damper or pulley of
crankshaft, align with the pointer in the timing case. Check that the
cylinder valves No. 1 should be closed (loose), otherwise turn the crankshaft
360º (one turn).

2.- Remove the access cover to the pin or nut of the drive gear.
injection pump (distribution box). Through one of the holes of the bolts
(superior) of the access cover, a rod is inserted that matches and enters a
hole in the injection pump drive gear. At this moment the
the pump and the motor are in sync or synchronized.

Note: It is not necessary to remove the gear to disassemble the injection pump.
pump control.

Measuring the adjustment rod: 4 - 4.5 mm in diameter and 80 mm in length

long.

IMPORTANT NOTE: The locking method and markings on the gears of

distribution is used when the injection pump has NOT been repaired and is mounted.
in the original engine.

B.- VERIFICATION AND ADJUSTMENT BY THE VALVE METHOD

DELIVERY:
Procedure:

1.- Remove the injection tube for cylinder No. 1.

2.- Remove the delivery valve holder.

3.- Remove from the delivery valve holder: the spring and the delivery valve, then
Reassemble the delivery valve holder in the pump.

4.-Place the fuel control lever (throttle) in the FULL position,

turn the crankshaft slowly in the normal direction while operating the pump
I filled it up and observed the position at which the fuel stops flowing out of the holder.
delivery valve.

5.- In the position where the fuel flow stops, check if the line
stamped on the crankshaft pulley to synchronize the injection, is aligned with
the pointer.
If the line has passed the pointer: the injection is delayed.
If the line did not reach the pointer: the injection is advanced.

6.- Adjust as follows:

A- Turn the crankshaft 30º to 40º in the opposite direction, starting at the
TOP position or PMS of compression of cylinder No. 1.
B- Align the line to synchronize the stamped injection on the crankshaft pulley
with the pointer, slowly rotating in the normal direction.
C- Loosen the nuts on the mounting flange of the pump and rotate the pump (body
from the pump) little by little; operating the priming pump until it stops flowing
the fuel outside the delivery valve holder.
D- Adjust the mounting flange nuts and check again the
synchronization. I stamped new marks on the flange.
Reassemble the delivery valve and the cylinder injection pipe.
No. 1
NOTE: The specifications on the levels of advancement for the tuning of the
injection pump, are found on the engine plate or the pump plate
injection.

IMPORTANT NOTE: The delivery or spill valve method is used when

the injection pump HAS been repaired or is being mounted on another engine or is a
NEW BOMB.

INJECTORS:
1.- Opening pressure:
Direct injection type injector: 200 Kg.cm2.
Swirl chamber type injector: 120 Kg.cm2.