Komatsu 95E-5 Series (KOHAG SPEC) Diesel Engine Shop Manual – PDF DOWNLOAD

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Komatsu 95E-5 Series (KOHAG SPEC) Diesel Engine Shop Manual

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Komatsu 95E-5 Series (KOHAG SPEC) Diesel Engine Shop Manual

Brands: Komatsu
Equipment Type: Diesel Engine
Manuals Type: Shop Manual
Machine Model: 95E-5 Series (KOHAG SPEC.) Engine
Book Code: SEN04357-00
Language: English
Pages: 326
File Format: Portable Document Format (PDF)

KOMATSU 95E-5 SERIES (KOHAG SPEC) DIESEL ENGINE SHOP MANUAL – PDF DOWNLOAD:

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DESCRIPTION:

Komatsu 95E-5 Series (KOHAG SPEC) 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 (KOHAG SPEC) Diesel Engine Shop Manual

SEN04357-00 WA90-6, WA100M-6..........................................................  1
00 Index and foreword.................................................................  3
	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...................................................................... 53
	Specification and technical data.................................................. 53
		Outline....................................................................... 54
		Specifications................................................................ 56
		General view.................................................................. 58
		Weight table.................................................................. 61
		Engine performance curves..................................................... 62
10 Structure, function and maintenance standard....................................... 67
	Structure, function and maintenance standard, Part 1.............................. 67
		General structure............................................................. 70
		Air intake and exhaust system................................................. 72
			Air intake and exhaust unit............................................... 72
			Turbocharger.............................................................. 74
		Engine unit................................................................... 78
			Cylinder head............................................................. 78
			Cylinder block............................................................ 80
			Cylinder.................................................................. 83
			Main moving parts......................................................... 84
			Crankshaft................................................................ 86
			Camshaft.................................................................. 87
			Piston, piston ring and piston pin........................................ 88
			Connecting rod............................................................ 89
			Flywheel and flywheel housing............................................. 90
			Timing gear............................................................... 92
			Valve system.............................................................. 96
			Valve, valve guide........................................................ 98
			Rocker arm shaft, push rod and tappet..................................... 99
	Structure, function and maintenance standard, Part 2..............................101
		Lubrication system............................................................103
			Lubrication system diagram................................................103
			Oil pump..................................................................104
			Regulator valve...........................................................106
			Oil filter................................................................107
		Fuel system...................................................................109
			Fuel system diagram.......................................................109
			Supply pump...............................................................110
			Fuel injection nozzle.....................................................112
			Fuel filter...............................................................113
			Common rail...............................................................114
			Various sensor............................................................116
		Cooling system................................................................118
			Cooling system diagram....................................................118
			Water pump................................................................119
			Cooling fan drive and thermostat..........................................122
		Electrical equipment..........................................................126
			Starting and charging system electrical circuit diagram...................126
			Alternator................................................................127
			Starting motor............................................................129
			Starting aid..............................................................130
			Engine controller.........................................................131
20 Standard value table...............................................................133
	Standard service value table......................................................133
		Standard service value table for testing, adjusting, and troubleshooting......134
		Running-in standard and performance test standard.............................135
30 Testing and adjusting..............................................................139
	Testing and adjusting.............................................................139
		Testing and adjusting tools list..............................................141
		Measuring intake air pressure.................................................142
		Testing exhaust temperature...................................................143
		Adjusting valve clearance.....................................................144
		Testing compression pressure..................................................146
		Testing blow-by pressure......................................................148
		Testing oil pressure..........................................................149
		Handling fuel system parts....................................................150
		Releasing residual pressure in fuel system....................................150
		Testing fuel pressure.........................................................151
		Reduced cylinder mode operation...............................................152
		No-injection cranking.........................................................152
		Testing leakage from pressure limiter and return rate from injector...........153
		Bleeding air from fuel circuit................................................156
		Testing fuel system for leakage...............................................158
		Testing and adjusting alternator belt tension.................................159
		Handling controller voltage circuit...........................................160
40 Troubleshooting....................................................................163
	General information on troubleshooting............................................163
		Points on troubleshooting.....................................................164
		Error code and failure code table.............................................166
		Information in troubleshooting table..........................................168
	Troubleshooting of electrical system (E-mode), Part 1.............................171
		E-1 Code [111/CA111] ECM Critical Internal Failure............................174
		E-2 Code [115/CA115] Eng. Ne and Bkup Speed Sensor Error......................177
		E-3 Code [122/CA122] Charge Air Press Sensor High Error.......................178
		E-4 Code [123/CA123] Charge Air Press Sensor Low Error........................180
		E-5 Code [131/CA131] Throttle Sensor High Error...............................181
		E-6 Code [132/CA132] Throttle Sensor Low Error................................184
		E-7 Code [144/CA144] Coolant Temp. Sensor High Error..........................185
		E-8 Code [145/CA145] Coolant Temp. Sensor Low Error...........................186
		E-9 Code [153/CA153] Charge Air Temp. Sensor High Error.......................188
		E-10 Code [154/CA154] Charge Air Temp. Sensor Low Error.......................190
		E-11 Code [187/CA187] Sensor Sup. 2 Volt. Low Error...........................191
		E-12 Code [221/CA221] Ambient Air Press. Sensor High Error....................192
		E-13 Code [222/CA222] Ambient Air Press. Sensor Low Error.....................194
		E-14 Code [227/CA227] Sensor Sup. 2 Volt. High Error..........................195
		E-15 Code [234/CA234] Eng. Overspeed..........................................197
		E-16 Code [238/CA238] Ne Speed Sensor Sup. Volt. Error........................198
		E-17 Code [271/CA271] IMV Short Error.........................................200
		E-18 Code [272/CA272] IMV Open Error..........................................202
		E-19 Code [322/CA322] Injector #1 (L/B #1) System Open/Short Error............204
		E-20 Code [324/CA324] Injector #3 (L/B #3) System Open/Short Error............206
		E-21 Code [331/CA331] Injector #2 (L/B #2) System Open/Short Error............208
		E-22 Code [332/CA332] Injector #4 (L/B #4) System Open/Short Error............210
		E-23 Code [351/CA351] INJ. Drive Circuit Error................................212
		E-24 Code [352/CA352] Sensor Sup. 1 Volt. Low Error...........................215
		E-25 Code [386/CA386] Sensor Sup. 1 Volt. High Error..........................216
		E-26 Code [431/CA431] Idle Validation SW Low error............................218
		E-27 Code [432/CA432] Idle Validation Process error...........................218
		E-28 Code [435/CA435] Abnormality in engine oil pressure switch...............219
		E-29 Code [441/CA441] Battery voltage low error...............................220
		E-30 Code [442/CA442] Battery voltage high error..............................220
	Troubleshooting of electrical system (E-mode), Part 2.............................223
		E-31 Code [449/CA449] Rail Press. Very High Error.............................225
		E-32 Code [451/CA451] Rail Press. Sensor High Error...........................226
		E-33 Code [452/CA452] Rail Press. Sensor Low Error............................228
		E-34 Code [553/CA553] Rail Press. High Error..................................229
		E-35 Code [559/CA559] Rail Press. Low Error...................................230
		E-36 Code [689/CA689] Eng. Ne Speed Sensor Error..............................234
		E-37 Code [731/CA731] Eng. Bkup Speed Sensor Phase Error......................236
		E-38 Code [757/CA757] All Persistent Data Lost Error..........................237
		E-39 Code [778/CA778] Eng. Bkup Speed Sensor Error............................238
		E-40 Code [1633/CA1633] KOMNET Dtalink Timeout Error..........................240
		E-41 Code [2185/CA2185] Throttle Sens. Sup. Volt. High Error..................241
		E-42 Code [2186/CA2186] Throttle Sens. Sup. Volt. Low Error...................244
		E-43 Code [2249/CA2249] Rail Press. Very Low Error............................245
		E-44 Code [2311/CA2311] Abnormality in IMV solenoid...........................246
		E-45 Code [2555/CA2555] Grid Heater Relay Volt. Low Error.....................248
		E-46 Code [2556/CA2556] Grid Heater Relay Volt. High Error....................250
		E-47 Code [(- - -)/B@BAZG] Eng. Oil press. Low Speed Derate...................252
		E-48 Code [(- - -)/B@BAZG] Eng. Oil press. Torque Derate......................252
		E-49 Code [(- - -)/B@BCNS] Eng. Overheat......................................253
	Troubleshooting of mechanical system (S-mode).....................................255
		Method of using troubleshooting charts........................................258
		S-1 Starting performance is poor..............................................262
		S-2 Engine does not start.....................................................263
		S-3 Engine does not pick up smoothly..........................................266
		S-4 Engine stops during operations............................................267
		S-5 Engine does not rotate smoothly...........................................268
		S-6 Engine lacks output (or lacks power)......................................269
		S-7 Exhaust smoke is black (incomplete combustion)............................270
		S-8 Oil consumption is excessive (or exhaust smoke is blue)...................271
		S-9 Oil becomes contaminated quickly..........................................272
		S-10 Fuel consumption is excessive............................................273
		S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)....274
		S-12 Oil pressure drops.......................................................275
		S-13 Oil level rises (Entry of coolant or fuel)...............................276
		S-14 Coolant temperature becomes too high (overheating).......................277
		S-15 Abnormal noise is made...................................................278
		S-16 Vibration is excessive...................................................279
50 Disassembly and assembly...........................................................281
	General information on disassembly and assembly...................................281
		How to read this manual.......................................................282
		Coating materials list........................................................283
		Special tools list............................................................286
	Disassembly and assembly, Part 1..................................................289
		General disassembly of engine.................................................290
	Disassembly and assembly, Part 2..................................................303
		General assembly of engine....................................................304
	Disassembly and assembly, Part 3..................................................321
		Disassembly and assembly procedure for fuel supply pump unit..................322
		Disassembly and assembly procedure for oil seal units.........................324

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