Komatsu ENGINE 95E-5 SERIES Shop Manual SEN01966-17 – PDF DOWNLOAD

Description

Komatsu ENGINE 95E-5 SERIES Shop Manual SEN01966-17 – PDF DOWNLOAD

FILE DETAILS:

Komatsu ENGINE 95E-5 SERIES Shop Manual SEN01966-17 – PDF DOWNLOAD

Language : English
Pages :454
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu ENGINE 95E-5 SERIES Shop Manual SEN01966-17 – PDF DOWNLOAD

1. General precautions 

Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully before operating the machine. In addition, read this manual and understand its contents before starting the work.

TABLE OF CONTENTS:

Komatsu ENGINE 95E-5 SERIES 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 head100
Cylinder block102
Cylinder105
Main moving parts106
Crankshaft108
Camshaft109
Piston, piston ring and piston pin110
Connecting rod111
Flywheel and flywheel housing114
Timing gear116
Valve system120
Valve, valve guide122
Rocker arm shaft, push rod and tappet123
Structure, function and maintenance standard, Part 2125
Lubrication system diagram127
Oil pump128
Regulator valve130
Oil filter131
Fuel system diagram133
Supply pump134
Fuel injection nozzle136
Fuel filter137
Common rail138
Various sensor140
Cooling system diagram142
Water pump143
Cooling fan drive and thermostat146
Starting and charging system electrical circuit diagram150
Alternator151
Starting motor155
Starting aid157
Engine controller158
20 Standard value table 0
Standard service value table161
Standard service value table for testing, adjusting, and troubleshooting162
Running-in standard and performance test standard169
30 Testing and adjusting 0
Testing and adjusting179
Testing and adjusting tools list181
Sketches of special tools183
Measuring intake air pressure184
Testing exhaust temperature185
Adjusting valve clearance186
Testing compression pressure188
Testing blow-by pressure190
Testing oil pressure191
Handling fuel system parts192
Releasing residual pressure in fuel system192
Testing fuel pressure193
Reduced cylinder mode operation194
No-injection cranking194
Testing leakage from pressure limiter and return rate from injector195
Bleeding air from fuel circuit198
Testing fuel system for leakage200
Testing and adjusting alternator belt tension201
Handling controller voltage circuit202
40 Troubleshooting 0
General information on troubleshooting205
Points on troubleshooting206
Error code and failure code table208
Information in troubleshooting table210
Connection table for connector pin numbers212
T- branch box and T- branch adapter table248
Troubleshooting of electrical system (E-mode), Part 1253
E-1 Code [111/CA111] ECM Critical Internal Failure256
E-2 Code [115/CA115] Eng Ne and Bkup Speed Sensor Error259
E-3 Code [122/CA122] Charge Air Press Sensor High Error260
E-4 Code [123/CA123] Charge Air Press Sensor Low Error262
E-5 Code [131/CA131] Throttle Sensor High Error263
E-6 Code [132/CA132] Throttle Sensor Low Error266
E-7 Code [144/CA144] Coolant Temp Sensor High Error268
E-8 Code [145/CA145] Coolant Temp Sensor Low Error270
E-9 Code [153/CA153] Charge Air Temp Sensor High Error272
E-10 Code [154/CA154] Charge Air Temp Sensor Low Error274
E-11 Code [187/CA187] Sensor Sup 2 Volt Low Error275
E-12 Code [221/CA221] Ambient Air Press Sensor High Error276
E-13 Code [222/CA222] Ambient Air Press Sensor Low Error278
E-14 Code [227/CA227] Sensor Sup 2 Volt High Error279
E-15 Code [234/CA234] Eng Overspeed280
E-16 Code [238/CA238] Ne Speed Sensor Sup Volt Error282
E-17 Code [271/CA271] IMV Short Error284
E-18 Code [272/CA272] IMV Open Error286
E-19 Code [322/CA322] Injector #1 System Open/Short Error288
E-20 Code [324/CA324] Injector #3 System Open/Short Error290
E-21 Code [331/CA331] Injector #2 System Open/Short Error292
E-22 Code [332/CA332] Injector #4 System Open/Short Error294
E-23 Code [351/CA351] INJ Drive Circuit Error296
E-24 Code [352/CA352] Sensor Sup 1 Volt Low Error299
E-25 Code [386/CA386] Sensor Sup 1 Volt High Error300
E-26 Code [431/CA431] Idle Validation SW Low error302
E-27 Code [432/CA432] Idle Validation Process error302
E-28 Code [435/CA435] Abnormality in engine oil pressure switch303
E-29 Code [441/CA441] Battery voltage low error304
E-30 Code [442/CA442] Battery voltage high error304
Troubleshooting of electrical system (E-mode), Part 2307
E-31 Code [449/CA449] Rail Press Very High Error309
E-32 Code [451/CA451] Rail Press Sensor High Error310
E-33 Code [452/CA452] Rail Press Sensor Low Error312
E-34 Code [553/CA553] Rail Press High Error313
E-35 Code [559/CA559] Rail Press Low Error314
E-36 Code [689/CA689] Eng Ne Speed Sensor Error318
E-37 Code [731/CA731] Eng Bkup Speed Sensor Phase Error320
E-38 Code [757/CA757] All Persistent Data Lost Error321
E-39 Code [778/CA778] Eng Bkup Speed Sensor Error322
E-40 Code [1633/CA1633] KOMNET Dtalink Timeout Error324
E-41 Code [2185/CA2185] Throttle Sens Sup Volt High Error325
E-42 Code [2186/CA2186] Throttle Sens Sup Volt Low Error328
E-43 Code [2249/CA2249] Rail Press Very Low Error329
E-44 Code [2311/CA2311] Abnormality in IMV solenoid330
E-45 Code [2555/CA2555] Grid Heater Relay Volt Low Error331
E-46 Code [2556/CA2556] Grid Heater Relay Volt High Error332
E-47 Code [(—)/B@BAZG] Eng Oil press Low Speed Derate334
E-48 Code [(—)/B@BAZG] Eng Oil press Torque Derate334
E-49 Code [(—)/B@BCNS] Eng Overheat335
Troubleshooting of mechanical system (S-mode)337
Method of using troubleshooting charts340
S-1 Starting performance is poor344
S-2 Engine does not start345
S-3 Engine does not pick up smoothly348
S-4 Engine stops during operations349
S-5 Engine does not rotate smoothly350
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 quickly354
S-10 Fuel consumption is excessive355
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)356
S-12 Oil pressure drops357
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 made360
S-16 Vibration is excessive361
50 Disassembly and assembly 0
General information on disassembly and assembly363
How to read this manual364
Coating materials list366
Special tools list369
Sketches of special tools370
Disassembly and assembly, Part 1373
General disassembly of engine374
Disassembly and assembly, Part 2387
General assembly of engine388
Disassembly and assembly, Part 3405
Disassembly and assembly procedure for fuel supply pump unit406
Disassembly and assembly procedure for oil seal units408
90 Repair and replacement of parts 0
Information related to repair and replacement411
Special tool table412
Sketches of special tools414
Parts related to cylinder head417
Part names related to cylinder head418
Testing and inspection of cylinder head419
Pressure test of cylinder head421
Replacement of valve guide421
Replacement of valve seat insert423
Repair of cylinder head mounting face by grinding429
Repair of valve by grinding430
Parts related to cylinder block433
Part names related to cylinder block434
Testing and inspection of cylinder block435
Part names related to crankshaft438
Testing and inspection of crankshaft439
Part names related to connecting rod440
Testing and inspection of connecting rod441
Replacement of flywheel ring gear442
Replacement of crankshaft gear443
Replacement of camshaft gear443
Replacement of connecting rod small end bushing444
Replacement of cam bushing446
Cylinder liner (Special part for repair)448
Rework drawing for counter bore449
Repair of crankshaft by grinding450

IMAGES PREVIEW OF THE MANUAL:

S.M 20/12/24