SHOW IMTAUNTU AIL KOMATSU 95 SERIES DIESEL ENGINE01 11 12 13 14 15 00-2 8 CONTENTS No. of page 01-001 GENERAL STRUCTURE AND FUNCTION... TESTING AND ADJUSTING 12-001 DISASSEMBLY AND ASSEMBLY MAINTENANCE STANDARD... REPAIR AND REPLACEMENT 95 SERIESLIST OF REVISED PAGES LIST OF REVISED PAGES. The affected pages are indicated by the use of the following marks. Its requested that necessary actions Mark Indication Action required be taken to these pages according to the table below. ©. | Page to be newly added Add © | Page to be replaced Replace ( }] Page to be deleted Discard Pages having no marks are those previously revised or made additions. LIST OF REVISED PAGE Mork Pege T™*!) stork Page TIME) mark Page TIME) Mork Page THM! 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LIST OF REVISED PAGES Mane Page Time otf ware Page Time t] ata Page MON tak Page TMF] ware Page Time ot 110964 row ® non @ 2026 © r20r2-102 @ 110965, so ® s202.28 © 2026 ® 12072-1038 ® 110966 row @ none © 026 @ 12022106 @ 110907 v010.15 @ 120228 © r2026 @ 2022405 @ 110968 von © 1200.26 © 120266 @ 1202206 @ 11097 non © seo2 © 0267 1202207 @ 1090 20 © s20228 © r20208 @ 12022:08 @ 109841 zoe @ 20220 © wo @ 12022:109 @ 10982 @ 205 @ 02” © 12027 @ | O w0210@ 10983 @ n0% rz021 © noun @ 203 ® 1098 ® non @ 2022 @ non ® nom @ 109 ® now @ noe @ 202.7 @ 0 | @ 10981 @ 201 @ nove @ nonn ® 206 @ 110992 © now2 @ 1202.35 © r207-18 ® nom @ 11093 @ | @ rows ® 12028 @ 1202276 ® 208 @ 110 @ now @ r20r237 on @ 120081 1401 @ 200 @ 120238 © 120278 @ | @ 1082 @ va @ 120290 © 20279 ®@ 1200 @ © 2001 ® wor © 120240 © 2020 ® 12001 @ 2002 ® r2021 © 20240 @ none @ 20902 @ 12003 @ 12022 @ noe @ one ® x2003 @ r2008 @ 2023 © ro @ v20289 @ s2004 @ 1205 @ 2024 @ rose © one @ 12008 @ 12006 @ 20258 @ 1202045 ® 20208 ® ros 207 ® 12026 @ 1202246 © 20208 ® 12007 @ 12008 @ 12027 @ r20247 @ none ® s2008 @ 12.0081 @ 2028 © reo © 2028 ® s2009 @ 12.000 @ 2029 © 120249 © 20209 1200010 © 010 ® 120210 @ 120250 © 20290 ® 20201 © 2001 ® 021 © r02s1 © 01 ® 2030-12 @ 120102 ® reo @ 20282 @ 2092 ®@ 1203013 @ r2003 © 1202213 @ 20259 @ 120299 @ ros014 @ r0104 @ ro @ n0onse @ none n20005 @ r2005 @ 1202215 @ 1202258 @ 120295 ® 202016 @ 120106 1202248 @ 102256 @ 120296 ® 20087 @ 2007 © 027 @ r0257 @ roner ®@ | 0 120001 @ nove @ 1202218 @ r0260 © rose @ | @ 0010 @ 2009 @ 1202219 @ 1202269 @ 2029 ® (92.020-20 201090 @ 1202220 @ 1202260 @ 12022100 | @ 12002 @ 201011 2022.21 @ 2026 @ voi @® | @ 1200022 @ 95 SERIES 00-2-3LIST OF REVISED PAGES LIST OF REVISED PAGES Mark Page TM®O) Mark Page TMP! mark Page TMP! mark Page TE! Mark Page Time of @ = 12-030-23 12050 @ 13-01-18 @ 13013 @ 13053 @ @ § 12-030-24 @ 12051 @ 13-01-19 © 13018 13054 @ @ = 12030-25 @ 12062 @ 13-00-20 @ 13015 @ 13055 @ @ §12030-26 @® 12063 @ 1300122 © 306 «@ 13.056 =@ @ = 1203027 12064 @ 13-001-23 © 307 @ 13057 @ © 2002 @ ros r2001.24 ® 08 @ 190571 @ © 1203029 1208 @ 13-001-25 @ 13019 @ 130588 @ 12030390 @ 12059 @ 13-01-26 @ 13020 «@ 13-089 «@® © 1203031 @ 1209 @ s200127 @ non @ 12080 @ © 20009 @ n2001 ®@ s200128 © 13202 @ 130601 © 12002 @ n2082 s200129 © non @ 3061 @ @ = 12.030-34 @ 12063 @ 13-001-30 @ 13-02 13062 @ © 1203035 @ 12066 13-001-31 @ 13025 13063 @ © 1202095 @ 120058 @ rs001-02 © 10% 1308 @ © 201037 @ 205 ron. ® 12061 ® 13088 @ © 12.030-38 12087 @ 13-001.34 @ 130277 @ 13066 = «@ © 200% @ 208 @ sa0128 @ wo @ 12067 @ © 01040 @ 200 @ 1300138 © 13200 @ 13068 = @ O 12.030-41 12070 @ 13-01-37 @ 13-0390 13070 @ OO 12.030-42 @) 12071 @ 13-001-38 @ 13031 @ 3071 @ © 203048 & nor ® 13.0019 rsa © won @ v0 1300140 © 13033 @ 0 ® rox 13001 @ 200141 @ nan @ non @ nox 1200-1 @ ra00142 ® 13035 @ 107 ® 12.034 130012 @ 13.:001-43 13038 @ 12035 120012 @® s300144 ® nar @ 14001 @ 12038 13-001-4 @ 13:001-45 @ 13038 | @ 14002 ner @ s2015 © 130140 © 09 @ 14002 @ noe @ ra010 @ s2.0147 © 00 @ v4002-1 ® new @ s2017 @ 1002 @ non @ 40002 ® 12-040 @ 13-001-8 13.03 «@ 302 «@ 14-004 1201 D 13.0019 @ 13-004 «@ 1308 @ 14-005 12002 @ 13.001-10 @ 13006 «= @ 13044 = @ 14-006 nos @ 300-11 © 12006 @ 308 @ 14007 @ 12004 @ 113-001-412 & 13007 @ 1306 @ 008 =D 1205 @ ra00112 13008 @ 07 @ 4008-1 @ 208 @ ra001-4 ® 1309 @ now @ 40002 @ nor ® s30015 @ ow @ 13050 @ 14000 @) 1208 @ r200116 @ non @ 3051 ® wo D 200 @ noon ® wor @ 13052 @ wor D 00-2-4 ‘95 SERIES @UST OF REVISED PAGES LIST OF REVISED PAGES Mark Page T™®T) Mark Page TIM! Mark Page TOK Mark Page TM? Of] Mark Page Time of “012 @ 16-006 ® 013 ® 18-007 ® 1401 @ 15008 ® 14.0132 @ 18-009 ®& woe = @ 15.010 @ nos @ 101 woe = =@ 15.012 0161 @ 15.013 4062 @ 15-014 uo @ 1.018 reore 016 ore. 1so17 ow2 @ ssor8 140183 @ isos 14020 © 14021 wo @ wo 14024 1402 14026 14.0261 14.0262 14027 14028 | 14029 14030 @ 14031 @ 14032 140332. 08 @ 14035 ® 15001 @ 15-002, ® won @ 95 SERIES‘SAFETY SAFETY SAFETY NOTICE 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 i is used to mark safety precautions in this manual. The cautions accompanying these symbols should always be followed care- fully. f any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation. GENERAL PRECAUTIONS: Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully BEFORE operating the machine. 1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine. 2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. « Always wear safety glasses when hitting parts with a hammer. + Always wear safety glasses when grind- ing parts with a grinder, etc. 3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, al- ways wear welding gloves, apron, hand shield, cap and other clothes suited for weld- ing work. 4, When carrying out any operation with two ‘or more workers, always agree on the oper- ating procedure before starting. Always in- form your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator's compartment. 6. Keep all tools in good condition and learn the correct way to use them. 6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. ‘Smoke only in the areas provided for smok- ing. Never smoke while working. PREPARATIONS FOR WORK 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 warn- ing signs on them. 9. When disassembling or assembling, support the machine with blocks, jacks or stands before starting work. 10. Remove all mud and oil from the steps or other places used to get on and off the ma- chine. 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