Komatsu 95E-5 Series Engine Shop Manual SEN01966-17 – PDF DOWNLOAD

Description

Komatsu 95E-5 Series Engine Shop Manual SEN01966-17 – PDF DOWNLOAD

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DESCRIPTION:

Komatsu 95E-5 Series Engine Shop Manual SEN01966-17 – PDF DOWNLOAD

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

TABLE OF CONTENTS:

Komatsu 95E-5 Series Engine Shop Manual SEN01966-17 – PDF DOWNLOAD

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 75
Engine performance curves 76
10 Structure, function and maintenance standard 0
Structure, function and maintenance standard, Part 1 87
General structure 90
Air intake and exhaust unit 92
Air cleaner 94
Turbocharger 96
Muffler 99
Cylinder head 100
Cylinder block 102
Cylinder 105
Main moving parts 106
Crankshaft 108
Camshaft 109
Piston, piston ring and piston pin 110
Connecting rod 111
Flywheel and flywheel housing 114
Timing gear 116
Valve system 120
Valve, valve guide 122
Rocker arm shaft, push rod and tappet 123
Structure, function and maintenance standard, Part 2 125
Lubrication system diagram 127
Oil pump 128
Regulator valve 130
Oil filter 131
Fuel system diagram 133
Supply pump 134
Fuel injection nozzle 136
Fuel filter 137
Common rail 138
Various sensor 140
Cooling system diagram 142
Water pump 143
Cooling fan drive and thermostat 146
Starting and charging system electrical circuit diagram 150
Alternator 151
Starting motor 155
Starting aid 157
Engine controller 158
20 Standard value table 0
Standard service value table 161
Standard service value table for testing, adjusting, and troubleshooting 162
Running-in standard and performance test standard 169
30 Testing and adjusting 0
Testing and adjusting 179
Testing and adjusting tools list 181
Sketches of special tools 183
Measuring intake air pressure 184
Testing exhaust temperature 185
Adjusting valve clearance 186
Testing compression pressure 188
Testing blow-by pressure 190
Testing oil pressure 191
Handling fuel system parts 192
Releasing residual pressure in fuel system 192
Testing fuel pressure 193
Reduced cylinder mode operation 194
No-injection cranking 194
Testing leakage from pressure limiter and return rate from injector 195
Bleeding air from fuel circuit 198
Testing fuel system for leakage 200
Testing and adjusting alternator belt tension 201
Handling controller voltage circuit 202
40 Troubleshooting 0
General information on troubleshooting 205
Points on troubleshooting 206
Error code and failure code table 208
Information in troubleshooting table 210
Connection table for connector pin numbers 212
T- branch box and T- branch adapter table 248
Troubleshooting of electrical system (E-mode), Part 1 253
E-1 Code [111/CA111] ECM Critical Internal Failure 256
E-2 Code [115/CA115] Eng Ne and Bkup Speed Sensor Error 259
E-3 Code [122/CA122] Charge Air Press Sensor High Error 260
E-4 Code [123/CA123] Charge Air Press Sensor Low Error 262
E-5 Code [131/CA131] Throttle Sensor High Error 263
E-6 Code [132/CA132] Throttle Sensor Low Error 266
E-7 Code [144/CA144] Coolant Temp Sensor High Error 268
E-8 Code [145/CA145] Coolant Temp Sensor Low Error 270
E-9 Code [153/CA153] Charge Air Temp Sensor High Error 272
E-10 Code [154/CA154] Charge Air Temp Sensor Low Error 274
E-11 Code [187/CA187] Sensor Sup 2 Volt Low Error 275
E-12 Code [221/CA221] Ambient Air Press Sensor High Error 276
E-13 Code [222/CA222] Ambient Air Press Sensor Low Error 278
E-14 Code [227/CA227] Sensor Sup 2 Volt High Error 279
E-15 Code [234/CA234] Eng Overspeed 280
E-16 Code [238/CA238] Ne Speed Sensor Sup Volt Error 282
E-17 Code [271/CA271] IMV Short Error 284
E-18 Code [272/CA272] IMV Open Error 286
E-19 Code [322/CA322] Injector #1 System Open/Short Error 288
E-20 Code [324/CA324] Injector #3 System Open/Short Error 290
E-21 Code [331/CA331] Injector #2 System Open/Short Error 292
E-22 Code [332/CA332] Injector #4 System Open/Short Error 294
E-23 Code [351/CA351] INJ Drive Circuit Error 296
E-24 Code [352/CA352] Sensor Sup 1 Volt Low Error 299
E-25 Code [386/CA386] Sensor Sup 1 Volt High Error 300
E-26 Code [431/CA431] Idle Validation SW Low error 302
E-27 Code [432/CA432] Idle Validation Process error 302
E-28 Code [435/CA435] Abnormality in engine oil pressure switch 303
E-29 Code [441/CA441] Battery voltage low error 304
E-30 Code [442/CA442] Battery voltage high error 304
Troubleshooting of electrical system (E-mode), Part 2 307
E-31 Code [449/CA449] Rail Press Very High Error 309
E-32 Code [451/CA451] Rail Press Sensor High Error 310
E-33 Code [452/CA452] Rail Press Sensor Low Error 312
E-34 Code [553/CA553] Rail Press High Error 313
E-35 Code [559/CA559] Rail Press Low Error 314
E-36 Code [689/CA689] Eng Ne Speed Sensor Error 318
E-37 Code [731/CA731] Eng Bkup Speed Sensor Phase Error 320
E-38 Code [757/CA757] All Persistent Data Lost Error 321
E-39 Code [778/CA778] Eng Bkup Speed Sensor Error 322
E-40 Code [1633/CA1633] KOMNET Dtalink Timeout Error 324
E-41 Code [2185/CA2185] Throttle Sens Sup Volt High Error 325
E-42 Code [2186/CA2186] Throttle Sens Sup Volt Low Error 328
E-43 Code [2249/CA2249] Rail Press Very Low Error 329
E-44 Code [2311/CA2311] Abnormality in IMV solenoid 330
E-45 Code [2555/CA2555] Grid Heater Relay Volt Low Error 331
E-46 Code [2556/CA2556] Grid Heater Relay Volt High Error 332
E-47 Code [(—)/B@BAZG] Eng Oil press Low Speed Derate 334
E-48 Code [(—)/B@BAZG] Eng Oil press Torque Derate 334
E-49 Code [(—)/B@BCNS] Eng Overheat 335
Troubleshooting of mechanical system (S-mode) 337
Method of using troubleshooting charts 340
S-1 Starting performance is poor 344
S-2 Engine does not start 345
S-3 Engine does not pick up smoothly 348
S-4 Engine stops during operations 349
S-5 Engine does not rotate smoothly 350
S-6 Engine lacks output (or lacks power) 351
S-7 Exhaust smoke is black (incomplete combustion) 352
S-8 Oil consumption is excessive (or exhaust smoke is blue) 353
S-9 Oil becomes contaminated quickly 354
S-10 Fuel consumption is excessive 355
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) 356
S-12 Oil pressure drops 357
S-13 Oil level rises (Entry of coolant or fuel) 358
S-14 Coolant temperature becomes too high (overheating) 359
S-15 Abnormal noise is made 360
S-16 Vibration is excessive 361
50 Disassembly and assembly 0
General information on disassembly and assembly 363
How to read this manual 364
Coating materials list 366
Special tools list 369
Sketches of special tools 370
Disassembly and assembly, Part 1 373
General disassembly of engine 374
Disassembly and assembly, Part 2 387
General assembly of engine 388
Disassembly and assembly, Part 3 405
Disassembly and assembly procedure for fuel supply pump unit 406
Disassembly and assembly procedure for oil seal units 408
90 Repair and replacement of parts 0
Information related to repair and replacement 411
Special tool table 412
Sketches of special tools 414
Parts related to cylinder head 417
Part names related to cylinder head 418
Testing and inspection of cylinder head 419
Pressure test of cylinder head 421
Replacement of valve guide 421
Replacement of valve seat insert 423
Repair of cylinder head mounting face by grinding 429
Repair of valve by grinding 430
Parts related to cylinder block 433
Part names related to cylinder block 434
Testing and inspection of cylinder block 435
Part names related to crankshaft 438
Testing and inspection of crankshaft 439
Part names related to connecting rod 440
Testing and inspection of connecting rod 441
Replacement of flywheel ring gear 442
Replacement of crankshaft gear 443
Replacement of camshaft gear 443
Replacement of connecting rod small end bushing 444
Replacement of cam bushing 446
Cylinder liner (Special part for repair) 448
Rework drawing for counter bore 449
Repair of crankshaft by grinding 450

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