Komatsu 95E-5 Series Diesel Engine Shop Manual SEN01966-15 – PDF DOWNLOAD

Description

Komatsu 95E-5 Series Diesel Engine Shop Manual

FILE DETAILS:

Komatsu 95E-5 Series Diesel Engine Shop Manual

Brands: Komatsu
Equipment Type: Diesel Engine
Manuals Type: Shop Manual
Machine Model: 95E-5 Series Engine
Book Code: SEN01966-15
Language: English
Pages: 448
File Format: Portable Document Format (PDF)

KOMATSU 95E-5 SERIES DIESEL ENGINE SHOP MANUAL SEN01966-15 – PDF DOWNLOAD:

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Komatsu 95E-5 Series Diesel Engine Shop Manual

How to read the shop manual:

1. Composition of shop manual:
   This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections.
   00. Index and foreword:
   This section explains the shop manuals list, table of contents, safety, and basic information.
   01. Specification:
   This section explains the specifications of the machine.
   10. Structure, function and maintenance standard:
   This section explains the structure, function, and maintenance standard values of each component. The structure and function sub-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. The maintenance standard sub-section explains the criteria and remedies for disassembly and service.
   20. Standard value table:
   This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting.
   30. Testing and adjusting:
   This section explains measuring instruments and measuring methods for testing and adjusting, and method of adjusting each part. The standard values and judgement criteria for testing and adjusting are explained in Testing and adjusting.
   40. Troubleshooting:
   This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
   50. Disassembly and assembly:
   This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque and quantity and weight of coating material, oil, grease, and coolant necessary for the work are also explained.
   90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume):

•  Chassis volume
  This section gives hydraulic circuit diagrams and electrical circuit diagrams.
•  Engine volume
  This section explains the method of reproducing, repairing, and replacing parts

TABLE OF CONTENTS:

Komatsu 95E-5 Series Diesel Engine Shop Manual

COVER
................................................................................  1
00 Index and foreword.................................................................  0
	Index.............................................................................  3
		Composition of shop manual....................................................  4
		Table of contents.............................................................  5
	Foreword and general information.................................................. 11
		Safety notice................................................................. 12
		How to read the shop manual................................................... 17
		Explanation of terms for maintenance standard................................. 19
		Handling of electric equipment and hydraulic component........................ 21
		Handling of connectors newly used for engines................................. 30
		How to read electric wire code................................................ 33
		Precautions when carrying out operation....................................... 36
		Method of disassembling and connecting push-pull type coupler................. 39
		Standard tightening torque table.............................................. 42
		Conversion table.............................................................. 46
01 Specification......................................................................  0
	Specification and technical data.................................................. 53
		General information........................................................... 54
		Specifications................................................................ 56
		General view.................................................................. 64
		Weight table.................................................................. 73
		Engine performance curves..................................................... 74
10 Structure, function and maintenance standard.......................................  0
	Structure, function and maintenance standard, Part 1.............................. 83
		General structure............................................................. 86
		Air intake and exhaust unit................................................... 88
		Air cleaner................................................................... 90
		Turbocharger.................................................................. 92
		Muffler....................................................................... 95
		Cylinder head................................................................. 96
		Cylinder block................................................................ 98
		Cylinder......................................................................101
		Main moving parts.............................................................102
		Crankshaft....................................................................104
		Camshaft......................................................................105
		Piston, piston ring and piston pin............................................106
		Connecting rod................................................................107
		Flywheel and flywheel housing.................................................110
		Timing gear...................................................................112
		Valve system..................................................................116
		Valve, valve guide............................................................118
		Rocker arm shaft, push rod and tappet.........................................119
	Structure, function and maintenance standard, Part 2..............................121
		Lubrication system diagram....................................................123
		Oil pump......................................................................124
		Regulator valve...............................................................126
		Oil filter....................................................................127
		Fuel system diagram...........................................................129
		Supply pump...................................................................130
		Fuel injection nozzle.........................................................132
		Fuel filter...................................................................133
		Common rail...................................................................134
		Various sensor................................................................136
		Cooling system diagram........................................................138
		Water pump....................................................................139
		Cooling fan drive and thermostat..............................................142
		Starting and charging system electrical circuit diagram.......................146
		Alternator....................................................................147
		Starting motor................................................................151
		Starting aid..................................................................153
		Engine controller.............................................................154
20 Standard value table...............................................................  0
	Standard service value table......................................................157
		Standard service value table for testing, adjusting, and troubleshooting......158
		Running-in standard and performance test standard.............................164
30 Testing and adjusting..............................................................  0
	Testing and adjusting.............................................................173
		Testing and adjusting tools list..............................................175
		Sketches of special tools.....................................................177
		Measuring intake air pressure.................................................178
		Testing exhaust temperature...................................................179
		Adjusting valve clearance.....................................................180
		Testing compression pressure..................................................182
		Testing blow-by pressure......................................................184
		Testing oil pressure..........................................................185
		Handling fuel system parts....................................................186
		Releasing residual pressure in fuel system....................................186
		Testing fuel pressure.........................................................187
		Reduced cylinder mode operation...............................................188
		No-injection cranking.........................................................188
		Testing leakage from pressure limiter and return rate from injector...........189
		Bleeding air from fuel circuit................................................192
		Testing fuel system for leakage...............................................194
		Testing and adjusting alternator belt tension.................................195
		Handling controller voltage circuit...........................................196
40 Troubleshooting....................................................................  0
	General information on troubleshooting............................................199
		Points on troubleshooting.....................................................200
		Error code and failure code table.............................................202
		Information in troubleshooting table..........................................204
		Connection table for connector pin numbers....................................206
		T- branch box and T- branch adapter table.....................................242
	Troubleshooting of electrical system (E-mode), Part 1.............................247
		E-1 Code [111/CA111] ECM Critical Internal Failure............................250
		E-2 Code [115/CA115] Eng. Ne and Bkup Speed Sensor Error......................253
		E-3 Code [122/CA122] Charge Air Press Sensor High Error.......................254
		E-4 Code [123/CA123] Charge Air Press Sensor Low Error........................256
		E-5 Code [131/CA131] Throttle Sensor High Error...............................257
		E-6 Code [132/CA132] Throttle Sensor Low Error................................260
		E-7 Code [144/CA144] Coolant Temp. Sensor High Error..........................262
		E-8 Code [145/CA145] Coolant Temp. Sensor Low Error...........................264
		E-9 Code [153/CA153] Charge Air Temp. Sensor High Error.......................266
		E-10 Code [154/CA154] Charge Air Temp. Sensor Low Error.......................268
		E-11 Code [187/CA187] Sensor Sup. 2 Volt. Low Error...........................269
		E-12 Code [221/CA221] Ambient Air Press. Sensor High Error....................270
		E-13 Code [222/CA222] Ambient Air Press. Sensor Low Error.....................272
		E-14 Code [227/CA227] Sensor Sup. 2 Volt. High Error..........................273
		E-15 Code [234/CA234] Eng. Overspeed..........................................274
		E-16 Code [238/CA238] Ne Speed Sensor Sup. Volt. Error........................276
		E-17 Code [271/CA271] IMV Short Error.........................................278
		E-18 Code [272/CA272] IMV Open Error..........................................280
		E-19 Code [322/CA322] Injector #1 System Open/Short Error.....................282
		E-20 Code [324/CA324] Injector #3 System Open/Short Error.....................284
		E-21 Code [331/CA331] Injector #2 System Open/Short Error.....................286
		E-22 Code [332/CA332] Injector #4 System Open/Short Error.....................288
		E-23 Code [351/CA351] INJ. Drive Circuit Error................................290
		E-24 Code [352/CA352] Sensor Sup. 1 Volt. Low Error...........................293
		E-25 Code [386/CA386] Sensor Sup. 1 Volt. High Error..........................294
		E-26 Code [431/CA431] Idle Validation SW Low error............................296
		E-27 Code [432/CA432] Idle Validation Process error...........................296
		E-28 Code [435/CA435] Abnormality in engine oil pressure switch...............297
		E-29 Code [441/CA441] Battery voltage low error...............................298
		E-30 Code [442/CA442] Battery voltage high error..............................298
	Troubleshooting of electrical system (E-mode), Part 2.............................301
		E-31 Code [449/CA449] Rail Press. Very High Error.............................303
		E-32 Code [451/CA451] Rail Press. Sensor High Error...........................304
		E-33 Code [452/CA452] Rail Press. Sensor Low Error............................306
		E-34 Code [553/CA553] Rail Press. High Error..................................307
		E-35 Code [559/CA559] Rail Press. Low Error...................................308
		E-36 Code [689/CA689] Eng. Ne Speed Sensor Error..............................312
		E-37 Code [731/CA731] Eng. Bkup Speed Sensor Phase Error......................314
		E-38 Code [757/CA757] All Persistent Data Lost Error..........................315
		E-39 Code [778/CA778] Eng. Bkup Speed Sensor Error............................316
		E-40 Code [1633/CA1633] KOMNET Dtalink Timeout Error..........................318
		E-41 Code [2185/CA2185] Throttle Sens. Sup. Volt. High Error..................319
		E-42 Code [2186/CA2186] Throttle Sens. Sup. Volt. Low Error...................322
		E-43 Code [2249/CA2249] Rail Press. Very Low Error............................323
		E-44 Code [2311/CA2311] Abnormality in IMV solenoid...........................324
		E-45 Code [2555/CA2555] Grid Heater Relay Volt. Low Error.....................325
		E-46 Code [2556/CA2556] Grid Heater Relay Volt. High Error....................326
		E-47 Code [(---)/B@BAZG] Eng. Oil press. Low Speed Derate.....................328
		E-48 Code [(---)/B@BAZG] Eng. Oil press. Torque Derate........................328
		E-49 Code [(---)/B@BCNS] Eng. Overheat........................................329
	Troubleshooting of mechanical system (S-mode).....................................331
		Method of using troubleshooting charts........................................334
		S-1 Starting performance is poor..............................................338
		S-2 Engine does not start.....................................................339
		S-3 Engine does not pick up smoothly..........................................342
		S-4 Engine stops during operations............................................343
		S-5 Engine does not rotate smoothly...........................................344
		S-6 Engine lacks output (or lacks power)......................................345
		S-7 Exhaust smoke is black (incomplete combustion)............................346
		S-8 Oil consumption is excessive (or exhaust smoke is blue)...................347
		S-9 Oil becomes contaminated quickly..........................................348
		S-10 Fuel consumption is excessive............................................349
		S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)....350
		S-12 Oil pressure drops.......................................................351
		S-13 Oil level rises (Entry of coolant or fuel)...............................352
		S-14 Coolant temperature becomes too high (overheating).......................353
		S-15 Abnormal noise is made...................................................354
		S-16 Vibration is excessive...................................................355
50 Disassembly and assembly...........................................................  0
	General information on disassembly and assembly...................................357
		How to read this manual.......................................................358
		Coating materials list........................................................360
		Special tools list............................................................363
		Sketches of special tools.....................................................364
	Disassembly and assembly, Part 1..................................................367
		General disassembly of engine.................................................368
	Disassembly and assembly, Part 2..................................................381
		General assembly of engine....................................................382
	Disassembly and assembly, Part 3..................................................399
		Disassembly and assembly procedure for fuel supply pump unit..................400
		Disassembly and assembly procedure for oil seal units.........................402
90 Repair and replacement of parts....................................................  0
	Information related to repair and replacement.....................................405
		Special tool table............................................................406
		Sketches of special tools.....................................................408
	Parts related to cylinder head....................................................411
		Part names related to cylinder head...........................................412
		Testing and inspection of cylinder head.......................................413
		Pressure test of cylinder head................................................415
		Replacement of valve guide....................................................415
		Replacement of valve seat insert..............................................417
		Repair of cylinder head mounting face by grinding.............................423
		Repair of valve by grinding...................................................424
	Parts related to cylinder block...................................................427
		Part names related to cylinder block..........................................428
		Testing and inspection of cylinder block......................................429
		Part names related to crankshaft..............................................432
		Testing and inspection of crankshaft..........................................433
		Part names related to connecting rod..........................................434
		Testing and inspection of connecting rod......................................435
		Replacement of flywheel ring gear.............................................436
		Replacement of crankshaft gear................................................437
		Replacement of camshaft gear..................................................437
		Replacement of connecting rod small end bushing...............................438
		Replacement of cam bushing....................................................440
		Cylinder liner (Special part for repair)......................................442
		Rework drawing for counter bore...............................................443
		Repair of crankshaft by grinding..............................................444

PLEASE NOTE:

• This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
• This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
• Require some other service manual or have any queries: please WRITE to us at [email protected]