Komatsu 95E-7 Series Engine Workshop Manual SEN06590-06 PDF

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Komatsu 95E-7 Series Engine Shop Manual SEN06590-06 – PDF DOWNLOAD

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Komatsu 95E-7 Series Engine Shop Manual SEN06590-06 – PDF DOWNLOAD

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Komatsu 95E-7 Series Engine Shop Manual SEN06590-06 – PDF DOWNLOAD

The Komatsu 95E-7 Series Engine Shop Manual SEN06590-06 is a comprehensive technical reference guide that provides detailed information on the maintenance, repair, and overhaul of the Komatsu 95E-7 Series diesel engine. This engine series is commonly used in heavy-duty applications such as construction equipment, mining vehicles, and marine vessels. The shop manual is an essential resource for mechanics, technicians, and service personnel who are responsible for servicing and maintaining these engines.

The Komatsu 95E-7 Series Engine Shop Manual is organized into several sections, each of which covers a specific aspect of the engine. These sections include:

1. General Information: This section provides an overview of the engine, including specifications, operating guidelines, and maintenance intervals.
2. Inspection and Adjustment: This section provides detailed instructions for inspecting and adjusting engine components, including the fuel injection system, valves, and timing belt.
3. Engine Assembly: This section covers the removal and installation of major engine components, such as the cylinder head, crankshaft, and pistons. The manual includes detailed illustrations and specifications to help technicians perform these tasks safely and efficiently.
4. Lubrication System: This section provides information on the engine’s lubrication system, including oil pump removal and installation, oil filter replacement, and oil pressure testing.
5. Cooling System: This section provides information on the engine’s cooling system, including water pump removal and installation, radiator removal and installation, and thermostat replacement.
6. Fuel System: This section covers the engine’s fuel system, including fuel pump removal and installation, fuel injector replacement, and fuel system troubleshooting.
7. Air Intake and Exhaust System: This section provides information on the engine’s air intake and exhaust system, including air filter replacement, turbocharger removal and installation, and exhaust manifold removal and installation.
8. Electrical System: This section provides information on the engine’s electrical system, including alternator and starter motor removal and installation, as well as troubleshooting procedures for electrical faults.
9. Special Tools: This section lists the special tools required for servicing the engine, including part numbers and illustrations.

The Komatsu 95E-7 Series Engine Shop Manual SEN06590-06 is an essential resource for maintaining and repairing these engines. It provides a comprehensive guide to servicing the engine and includes detailed instructions, specifications, and illustrations to help technicians perform tasks accurately and safely. The manual is a valuable tool for ensuring that the Komatsu 95E-7 Series diesel engine continues to operate at peak performance, with maximum efficiency and reliability over its long service life.

TABLE OF CONTENTS:

Komatsu 95E-7 Series Engine Shop Manual SEN06590-06 – PDF DOWNLOAD

COVER……………………………………………………………………………………………………………………… 1
00 INDEX AND FOREWORD………………………………………………………………………………………………………. 3
INDEX…………………………………………………………………………………………………………………. 4
ABBREVIATION LIST………………………………………………………………………………………………………. 6
FOREWORD, SAFETY, BASIC INFORMATION………………………………………………………………………………………. 12
HOW TO READ THE ENGINE SHOP MANUAL……………………………………………………………………………………. 12
SAFETY NOTICE FOR OPERATION………………………………………………………………………………………….. 14
PRECAUTIONS TO PREVENT FIRE………………………………………………………………………………………….. 22
ACTIONS IF FIRE OCCURS………………………………………………………………………………………………. 24
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS…………………………………………………………………………… 25
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS………………………………………………………………………….. 26
PRECAUTIONS FOR DEF…………………………………………………………………………………………………. 27
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING……………………………………………………………………… 27
PRECAUTIONS FOR ADDING…………………………………………………………………………………………… 27
PRECAUTIONS FOR STORING………………………………………………………………………………………….. 27
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE……………………………………………………………………………. 27
THE OTHER PRECAUTIONS……………………………………………………………………………………………. 27
STORE AdBlue/DEF……………………………………………………………………………………………………. 28
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT…………………………………………………………………………… 29
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS…………………………………………………………………. 32
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT………………………………………………………………………….. 39
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT…………………………………………………………………………. 41
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT……………………………………………………………………….. 42
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER………………………………………………………………………….. 43
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER…………………………………………………. 43
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER…………………………………………………. 44
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER…………………………………………………. 45
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS………………………………………………………………. 47
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR……………………………………………………………….. 51
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR………………………………………………………… 52
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL………………………………………………………. 54
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH………………………………………………………. 55
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE………………………………………………….. 57
HOW TO READ ELECTRICAL WIRE CODE……………………………………………………………………………………… 58
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD………………………………………………………………………….. 62
STANDARD TIGHTENING TORQUE TABLE……………………………………………………………………………………… 65
CONVERSION TABLE……………………………………………………………………………………………………. 72
01 SPECIFICATIONS………………………………………………………………………………………………………….. 77
CONTENTS………………………………………………………………………………………………………………. 78
ABBREVIATION LIST………………………………………………………………………………………………………. 79
SPECIFICATIONS…………………………………………………………………………………………………………. 85
OUTLINE OF EXHAUST GAS REGULATION…………………………………………………………………………………….. 85
SYSTEM DRAWINGS OF ENGINE CONFORMED TO TIER4 REGULATION……………………………………………………………… 87
IMPROVED POINTS OF ENGINE CONFORMED TO TIER4 REGULATION……………………………………………………………… 88
LIST OF APPLICABLE MACHINES: 95LE-7…………………………………………………………………………………… 89
SPECIFICATIONS……………………………………………………………………………………………………… 90
SPECIFICATIONS: SAA4D95LE-7 (D37EX-24, D37EXI-24, D37PX-24, D37PXI-24)………………………………………………… 90
SPECIFICATIONS: SAA4D95LE-7 (D39EX-24, D39EXI-24, D39PX-24, D39PXI-24)………………………………………………… 91
SPECIFICATIONS: SAA4D95LE-7 (PC130-11)…………………………………………………………………………….. 92
SPECIFICATIONS: SAA4D95LE-7 (PC138US-11, PC138USLC-11, PC138US-11E0)………………………………………………….. 93
ENGINE GENERAL VIEW…………………………………………………………………………………………………. 94
ENGINE GENERAL VIEW: SAA4D95LE-7 (D37EX-24, D37EXI-24, D37PX-24, D37PXI-24, D39EX-24, D39EXI-24, D39PX-24, D39PXI-24)………. 94
ENGINE GENERAL VIEW: SAA4D95LE-7 (PC130-11)………………………………………………………………………… 98
ENGINE GENERAL VIEW: SAA4D95LE-7 (PC138US-11, PC138USLC-11, PC138US-11E0)………………………………………………102
WEIGHT TABLE………………………………………………………………………………………………………..106
WEIGHT TABLE: 95LE-7……………………………………………………………………………………………..106
ENGINE PERFORMANCE CURVE……………………………………………………………………………………………..108
ENGINE PERFORMANCE CURVE: SAA4D95LE-7(D37EX-24, D37EXI-24, D37PX-24, D37PXI-24)…………………………………………108
ENGINE PERFORMANCE CURVE: SAA4D95LE-7(D39EX-24, D39EXI-24, D39PX-24, D39PXI-24)…………………………………………109
ENGINE PERFORMANCE CURVE: SAA4D95LE-7(PC130-11)……………………………………………………………………..110
ENGINE PERFORMANCE CURVE: SAA4D95LE-7(PC138US-11, PC138USLC-11, PC138US-11E0)…………………………………………..111
10 STRUCTURE AND FUNCTION……………………………………………………………………………………………………113
CONTENTS……………………………………………………………………………………………………………….114
ABBREVIATION LIST……………………………………………………………………………………………………….116
UREA SCR SYSTEM…………………………………………………………………………………………………………122
LAYOUT DRAWING OF UREA SCR SYSTEM……………………………………………………………………………………..122
SYSTEM DIAGRAM OF UREA SCR SYSTEM (FOR THE ENGINES COMPLIED WITH TIER 4 FINAL REGULATION)……………………………………124
SYSTEM DIAGRAM OF UREA SCR SYSTEM (FOR THE ENGINES COMPLIED WITH EU STAGE V REGULATION)……………………………………..125
FUNCTION OF UREA SCR SYSTEM…………………………………………………………………………………………..127
FUNCTION OF AdBlue/DEF SUPPLY SYSTEM……………………………………………………………………………….127
INDUCEMENT STRATEGY………………………………………………………………………………………………129
COMPONENT PARTS OF UREA SCR SYSTEM…………………………………………………………………………………….145
AdBlue/DEF MIXING TUBE……………………………………………………………………………………………145
SCR ASSEMBLY…………………………………………………………………………………………………….146
AdBlue/DEF TANK………………………………………………………………………………………………….148
AdBlue/DEF PUMP………………………………………………………………………………………………….150
AdBlue/DEF INJECTOR………………………………………………………………………………………………151
AdBlue/DEF HOSE………………………………………………………………………………………………….152
AdBlue/DEF TANK HEATING VALVE……………………………………………………………………………………..153
ENGINE SYSTEM…………………………………………………………………………………………………………..154
LAYOUT OF ENGINE COMPONENTS…………………………………………………………………………………………..154
LAYOUT DRAWING OF ENGINE COMPONENTS………………………………………………………………………………..154
INTAKE AND EXHAUST SYSTEM PARTS……………………………………………………………………………………….158
LAYOUT DRAWING OF INTAKE AND EXHAUST SYSTEM…………………………………………………………………………158
INTAKE AND EXHAUST SYSTEM CIRCUIT DIAGRAM…………………………………………………………………………..159
FUNCTION OF INTAKE AND EXHAUST SYSTEM………………………………………………………………………………159
AIR CLEANER……………………………………………………………………………………………………..161
INTAKE AIR HEATER………………………………………………………………………………………………..162
ENGINE MAIN BODY PARTS……………………………………………………………………………………………….163
CYLINDER HEAD……………………………………………………………………………………………………163
CYLINDER BLOCK…………………………………………………………………………………………………..166
MAIN MOVING PARTS………………………………………………………………………………………………..168
TIMING GEAR……………………………………………………………………………………………………..171
FRONT COVER……………………………………………………………………………………………………..173
VALVE SYSTEM…………………………………………………………………………………………………….174
FLYWHEEL AND FLYWHEEL HOUSING……………………………………………………………………………………..177
TURBOCHARGER SYSTEM………………………………………………………………………………………………….178
VARIABLE FLOW TURBOCHARGER………………………………………………………………………………………..178
EGR SYSTEM………………………………………………………………………………………………………182
EGR VALVE……………………………………………………………………………………………………….185
EGR COOLER………………………………………………………………………………………………………187
KCCV SYSTEM……………………………………………………………………………………………………..189
KCCV VENTILATOR………………………………………………………………………………………………….194
EXHAUST THROTTLE VALVE……………………………………………………………………………………………196
KDOC……………………………………………………………………………………………………………197
KDPF……………………………………………………………………………………………………………200
LUBRICATION SYSTEM…………………………………………………………………………………………………..205
LAYOUT DRAWING OF LUBRICATION SYSTEM PARTS………………………………………………………………………….205
LUBRICATION SYSTEM CIRCUIT DIAGRAM…………………………………………………………………………………206
ENGINE OIL PUMP………………………………………………………………………………………………….207
ENGINE OIL FILTER………………………………………………………………………………………………..209
ENGINE OIL COOLER………………………………………………………………………………………………..211
ENGINE OIL PAN…………………………………………………………………………………………………..212
FUEL SYSTEM…………………………………………………………………………………………………………213
LAYOUT DRAWING OF FUEL SYSTEM PARTS………………………………………………………………………………..213
FUEL SYSTEM CIRCUIT DIAGRAM……………………………………………………………………………………….214
FUNCTION OF FUEL SYSTEM…………………………………………………………………………………………..214
SUPPLY PUMP……………………………………………………………………………………………………..215
COMMON RAIL……………………………………………………………………………………………………..216
INJECTOR………………………………………………………………………………………………………..217
FUEL PREFILTER…………………………………………………………………………………………………..220
FUEL MAIN FILTER…………………………………………………………………………………………………221
COOLING SYSTEM………………………………………………………………………………………………………222
LAYOUT DRAWING OF COOLING SYSTEM PARTS……………………………………………………………………………..222
COOLING SYSTEM CIRCUIT DIAGRAM…………………………………………………………………………………….223
DRIVE PULLEY…………………………………………………………………………………………………….224
WATER PUMP………………………………………………………………………………………………………226
THERMOSTAT………………………………………………………………………………………………………227
JIGGLE VALVE…………………………………………………………………………………………………….230
ELECTRICAL SYSTEM……………………………………………………………………………………………………….231
COMPONENT PARTS OF ELECTRICAL SYSTEM…………………………………………………………………………………..231
ALTERNATOR………………………………………………………………………………………………………231
STARTING MOTOR…………………………………………………………………………………………………..234
ENGINE WIRING HARNESS…………………………………………………………………………………………….237
ENGINE CONTROLLER………………………………………………………………………………………………..239
SENSOR……………………………………………………………………………………………………………..246
LAYOUT DRAWING OF ENGINE SENSOR (FOR THE ENGINES COMPLIED WITH TIER 4 FINAL REGULATION)………………………………….246
LAYOUT DRAWING OF ENGINE SENSOR (FOR THE ENGINES COMPLIED WITH EU STAGE V REGULATION)……………………………………248
STRUCTURE OF AMBIENT PRESSURE SENSOR……………………………………………………………………………….249
FUNCTION OF AMBIENT PRESSURE SENSOR………………………………………………………………………………..249
STRUCTURE OF ENGINE OIL PRESSURE SWITCH…………………………………………………………………………….250
FUNCTION OF ENGINE OIL PRESSURE SWITCH……………………………………………………………………………..250
STRUCTURE OF CHARGE (BOOST) PRESSURE AND TEMPERATURE SENSOR…………………………………………………………..251
FUNCTION OF CHARGE (BOOST) PRESSURE AND TEMPERATURE SENSOR……………………………………………………………251
STRUCTURE OF COOLANT TEMPERATURE SENSOR…………………………………………………………………………….252
FUNCTION OF COOLANT TEMPERATURE SENSOR……………………………………………………………………………..252
STRUCTURE OF NE (CRANKSHAFT) SPEED SENSOR…………………………………………………………………………..253
FUNCTION OF NE (CRANKSHAFT) SPEED SENSOR……………………………………………………………………………253
STRUCTURE OF Bkup (CAMSHAFT) SPEED SENSOR…………………………………………………………………………..253
FUNCTION OF Bkup (CAMSHAFT) SPEED SENSOR……………………………………………………………………………254
STRUCTURE OF COMMON RAIL PRESSURE SENSOR……………………………………………………………………………255
FUNCTION OF COMMON RAIL PRESSURE SENSOR…………………………………………………………………………….255
STRUCTURE OF MASS AIR FLOW AND TEMPERATURE SENSOR……………………………………………………………………256
FUNCTION OF MASS AIR FLOW AND TEMPERATURE SENSOR…………………………………………………………………….256
STRUCTURE OF KDPF DIFFERENTIAL PRESSURE AND OUTLET PRESSURE SENSOR…………………………………………………….257
FUNCTION OF KDPF DIFFERENTIAL PRESSURE AND OUTLET PRESSURE SENSOR……………………………………………………..257
STRUCTURE OF CRANKCASE PRESSURE SENSOR……………………………………………………………………………..258
FUNCTION OF CRANKCASE PRESSURE SENSOR………………………………………………………………………………258
STRUCTURE OF ENGINE OIL LEVEL SENSOR……………………………………………………………………………….259
FUNCTION OF ENGINE OIL LEVEL SENSOR………………………………………………………………………………..259
STRUCTURE OF AIR CLEANER CLOGGING SENSOR……………………………………………………………………………260
FUNCTION OF AIR CLEANER CLOGGING SENSOR…………………………………………………………………………….260
STRUCTURE OF EGR VALVE (WITH BUILT-IN POSITION SENSOR)……………………………………………………………….261
FUNCTION OF EGR VALVE (WITH BUILT-IN POSITION SENSOR)………………………………………………………………..261
STRUCTURE OF VARIABLE FLOW TURBOCHARGER MOTOR (WITH BUILT-IN POSITION SENSOR)…………………………………………..262
FUNCTION OF VARIABLE FLOW TURBOCHARGER MOTOR (WITH BUILT-IN POSITION SENSOR)……………………………………………262
STRUCTURE OF EXHAUST THROTTLE VALVE (WITH BUILT-IN POSITION SENSOR)……………………………………………………263
FUNCTION OF EXHAUST THROTTLE VALVE (WITH BUILT-IN POSITION SENSOR)…………………………………………………….263
20 STANDARD VALUE TABLE……………………………………………………………………………………………………..265
CONTENTS……………………………………………………………………………………………………………….266
ABBREVIATION LIST……………………………………………………………………………………………………….267
STANDARD VALUE TABLE FOR ENGINE…………………………………………………………………………………………..273
STANDARD VALUE TABLE FOR ENGINE: SAA4D95LE-7(D37EX-24, D37EXI-24, D37PX-24, D37PXI-24,D39EX-24, D39EXI-24, D39PX-24, D39PXI-24)….273
STANDARD VALUE TABLE FOR ENGINE: SAA4D95LE-7 (PC130-11)………………………………………………………………….275
STANDARD VALUE TABLE FOR ENGINE: SAA4D95LE-7 (PC138US-11, PC138USLC-11, PC138US-11E0)……………………………………….277
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD…………………………………………………………………………..279
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA4D95LE-7(D37EX-24,D37EXI-24,D37PX-24,D37PXI-24)…………………………279
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA4D95LE-7(D39EX-24,D39EXI-24,D39PX-24,D39PXI-24)…………………………281
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA4D95LE-7 (PC130-11)………………………………………………….283
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA4D95LE-7 (PC138US-11, PC138USLC-11, PC138US-11E0)……………………….285
50 DISASSEMBLY AND ASSEMBLY………………………………………………………………………………………………….287
CONTENTS……………………………………………………………………………………………………………….288
ABBREVIATION LIST……………………………………………………………………………………………………….289
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY…………………………………………………………………………….295
HOW TO READ THIS MANUAL………………………………………………………………………………………………295
COATING MATERIALS LIST……………………………………………………………………………………………….297
SPECIAL TOOLS LIST…………………………………………………………………………………………………..301
SKETCHES OF SPECIAL TOOLS…………………………………………………………………………………………….303
ENGINE SYSTEM…………………………………………………………………………………………………………..305
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY………………………………………………………………………………305
DISASSEMBLE ENGINE GENERALLY………………………………………………………………………………………306
ASSEMBLE ENGINE GENERALLY…………………………………………………………………………………………332
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY………………………………………………………………………………..371
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY……………………………………………………………………………371
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY………………………………………………………………………….374
REMOVE AND INSTALL ENGINE FRONT OIL SEAL……………………………………………………………………………….377
METHOD FOR REMOVING ENGINE FRONT OIL SEAL…………………………………………………………………………..377
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL…………………………………………………………………………378
REMOVE AND INSTALL ENGINE REAR OIL SEAL………………………………………………………………………………..380
METHOD FOR REMOVING ENGINE REAR OIL SEAL……………………………………………………………………………380
METHOD FOR INSTALLING ENGINE REAR OIL SEAL………………………………………………………………………….381
60 MAINTENANCE STANDARD……………………………………………………………………………………………………..383
CONTENTS……………………………………………………………………………………………………………….384
ABBREVIATION LIST……………………………………………………………………………………………………….385
ENGINE SYSTEM…………………………………………………………………………………………………………..391
INTAKE AND EXHAUST SYSTEM PARTS……………………………………………………………………………………….391
MAINTENANCE STANDARD OF VARIABLE FLOW TURBOCHARGER…………………………………………………………………..391
ENGINE MAIN BODY PARTS……………………………………………………………………………………………….392
MAINTENANCE STANDARD OF CYLINDER HEAD………………………………………………………………………………392
MAINTENANCE STANDARD OF CYLINDER BLOCK……………………………………………………………………………..394
MAINTENANCE STANDARD OF CRANKSHAFT…………………………………………………………………………………397
MAINTENANCE STANDARD OF PISTON…………………………………………………………………………………….399
MAINTENANCE STANDARD OF CONROD…………………………………………………………………………………….401
MAINTENANCE STANDARD OF TIMING GEAR………………………………………………………………………………..403
MAINTENANCE STANDARD OF CAMSHAFT…………………………………………………………………………………..404
MAINTENANCE STANDARD OF VALVE AND VALVE GUIDE……………………………………………………………………….406
MAINTENANCE STANDARD OF ROCKER ARM…………………………………………………………………………………408
MAINTENANCE STANDARD OF TAPPET…………………………………………………………………………………….410
MAINTENANCE STANDARD OF FLYWHEEL…………………………………………………………………………………..411
LUBRICATION SYSTEM…………………………………………………………………………………………………..413
MAINTENANCE STANDARD OF ENGINE OIL PUMP…………………………………………………………………………….413
COOLING SYSTEM………………………………………………………………………………………………………415
MAINTENANCE STANDARD OF WATER PUMP…………………………………………………………………………………415
INDEX………………………………………………………………………………………………………………………417

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