Komatsu 95E-5 Series Engine Shop Manual SEN01966-16 – PDF DOWNLOAD
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Komatsu 95E-5 Series Engine Shop Manual SEN01966-16 – PDF DOWNLOAD
Description
Komatsu 95E-5 Series Engine Shop Manual SEN01966-16 – PDF DOWNLOAD
FILE DETAILS:
Komatsu 95E-5 Series Engine Shop Manual SEN01966-16 – PDF DOWNLOAD
Language : English
Pages : 448
Downloadable : Yes
File Type : PDF
Size: 18.4 MB
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DESCRIPTION:
Komatsu 95E-5 Series Engine Shop Manual SEN01966-16 – PDF DOWNLOAD
The Komatsu 95E-5 Series Engine Shop Manual, also known as the SEN01966-16 manual, is a comprehensive guide to servicing, maintaining, and repairing the Komatsu 95E-5 series engine. The manual is published by Komatsu, a leading manufacturer of heavy equipment and construction machinery, and is designed for use by qualified mechanics and technicians.
The Komatsu 95E-5 series engine is a diesel engine commonly used in a range of heavy equipment, such as excavators, bulldozers, and loaders. The manual covers all aspects of the engine, including its specifications, features, and operating principles. It is an essential tool for anyone who works with Komatsu equipment that is powered by this engine.
The manual is divided into several sections, each of which provides specific information on different aspects of the engine. The sections include:
- General information: This section provides an overview of the engine, including its specifications, features, and operating principles. It also includes information on safety precautions, tools, and equipment needed for maintenance and repair.
- Inspection and adjustment: This section provides detailed instructions on how to inspect and adjust various components of the engine, including the cylinder head, valves, fuel system, and cooling system.
- Engine disassembly and assembly: This section provides step-by-step instructions on how to disassemble and assemble the engine. It includes detailed diagrams and illustrations to help users understand each step of the process.
- Troubleshooting: This section provides a comprehensive list of potential problems that may arise with the engine, along with diagnostic procedures to help identify and fix these issues.
- Maintenance: This section provides information on the regular maintenance tasks that should be performed on the engine, including oil changes, filter replacements, and other routine tasks.
- Reassembly and testing: This section provides detailed instructions on how to reassemble the engine after repairs have been made. It also includes information on how to test the engine to ensure that it is functioning properly.
- Service data: This section provides detailed technical data on the engine, including torque specifications, compression pressures, and other important information.
The manual is written in clear, concise language and is filled with detailed diagrams and illustrations to help users understand each step of the process. It is an essential tool for anyone who works with Komatsu engines and can help to ensure that the engine is maintained and repaired to the highest standards. However, it should be noted that the manual is designed for use by qualified mechanics and technicians and should not be used by individuals without the appropriate training and experience.
TABLE OF CONTENTS:
Komatsu 95E-5 Series Engine Shop Manual SEN01966-16 – PDF DOWNLOAD
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
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