Komatsu Engine 95E -7 SERIES Shop Manual SEN06590-07 PDF

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Komatsu Engine 95E -7 SERIES Shop Manual SEN06590-07 – PDF DOWNLOAD

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Komatsu Engine 95E -7 SERIES Shop Manual SEN06590-07 – PDF DOWNLOAD

Language : English
Pages :424
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu Engine 95E -7 SERIES Shop Manual SEN06590-07 – PDF DOWNLOAD

FOREWORD, SAFETY, BASIC INFORMATION
HOW TO READ THE ENGINE SHOP MANUAL
• Some of the attachments and options described in this shop manual may not be available in some areas. If
they are required, consult your Komatsu distributor.
• The materials and specifications are subject to change without notice.
• Shop manuals are available for “machine part” and “engine part”. For the engine unit, see the shop manual
for the machine which has the same engine model.
• Actual machine may differ from the images which are contained in this manual. A typical model is shown in
the illustrations of this shop manual.
Composition of the shop manual
This shop manual contains technical information necessary to perform services in workshops. It is divided into
the following chapters for the ease of use.
00 INDEX AND FOREWORD
This section describes the index, foreword, safety, and basic information.
01 SPECIFICATIONS
This section describes the specifications of the machine.
10 STRUCTURE AND FUNCTION
This section describes the structure and operation of each component with respect to each system. “STRUCTURE
AND FUNCTION” is helpful in not only understanding the structure of each component but performing
troubleshooting.
20 STANDARD VALUE TABLE
This section describes the standard values for new machine and failure criteria for testing and adjusting, and
troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge
troubles in troubleshooting.
50 DISASSEMBLY AND ASSEMBLY
This section describes the special tools, work procedures, and safety precautions necessary for removal, installation,
disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and
weight of the coating materials, lubricants, and coolant necessary to these works are shown.
60 MAINTENANCE STANDARD
This section describes the maintenance standard value of each component. The maintenance standard shows
the criteria and remedies for disassembly and assembly.

TABLE OF CONTENTS:

Komatsu Engine 95E -7 SERIES Shop Manual SEN06590-07 – 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, PC130LC-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, PC130LC-11) 98
ENGINE GENERAL VIEW: SAA4D95LE-7 (PC138US-11, PC138USLC-11, PC138US-11E0)102
WEIGHT TABLE106
WEIGHT TABLE: 95LE-7106
ENGINE PERFORMANCE CURVE108
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, PC130LC-11)110
ENGINE PERFORMANCE CURVE: SAA4D95LE-7(PC138US-11, PC138USLC-11, PC138US-11E0)111
10 STRUCTURE AND FUNCTION113
CONTENTS114
ABBREVIATION LIST116
UREA SCR SYSTEM122
LAYOUT DRAWING OF UREA SCR SYSTEM122
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 SYSTEM127
FUNCTION OF AdBlue/DEF SUPPLY SYSTEM127
INDUCEMENT STRATEGY129
COMPONENT PARTS OF UREA SCR SYSTEM145
AdBlue/DEF MIXING TUBE145
SCR ASSEMBLY146
AdBlue/DEF TANK148
AdBlue/DEF PUMP150
AdBlue/DEF INJECTOR151
AdBlue/DEF HOSE152
AdBlue/DEF TANK HEATING VALVE153
ENGINE SYSTEM154
LAYOUT OF ENGINE COMPONENTS154
LAYOUT DRAWING OF ENGINE COMPONENTS154
INTAKE AND EXHAUST SYSTEM PARTS158
LAYOUT DRAWING OF INTAKE AND EXHAUST SYSTEM158
INTAKE AND EXHAUST SYSTEM CIRCUIT DIAGRAM159
FUNCTION OF INTAKE AND EXHAUST SYSTEM159
AIR CLEANER161
INTAKE AIR HEATER162
ENGINE MAIN BODY PARTS163
CYLINDER HEAD163
CYLINDER BLOCK166
MAIN MOVING PARTS168
TIMING GEAR171
FRONT COVER173
VALVE SYSTEM174
FLYWHEEL AND FLYWHEEL HOUSING177
TURBOCHARGER SYSTEM178
VARIABLE FLOW TURBOCHARGER178
EGR SYSTEM182
EGR VALVE185
EGR COOLER187
KCCV SYSTEM189
KCCV VENTILATOR194
EXHAUST THROTTLE VALVE196
KDOC197
KDPF200
LUBRICATION SYSTEM205
LAYOUT DRAWING OF LUBRICATION SYSTEM PARTS205
LUBRICATION SYSTEM CIRCUIT DIAGRAM206
ENGINE OIL PUMP207
ENGINE OIL FILTER209
ENGINE OIL COOLER211
ENGINE OIL PAN212
FUEL SYSTEM213
LAYOUT DRAWING OF FUEL SYSTEM PARTS213
FUEL SYSTEM CIRCUIT DIAGRAM214
FUNCTION OF FUEL SYSTEM214
SUPPLY PUMP215
COMMON RAIL216
INJECTOR217
FUEL PREFILTER220
FUEL MAIN FILTER221
COOLING SYSTEM222
LAYOUT DRAWING OF COOLING SYSTEM PARTS222
COOLING SYSTEM CIRCUIT DIAGRAM223
DRIVE PULLEY224
WATER PUMP226
THERMOSTAT227
JIGGLE VALVE230
ELECTRICAL SYSTEM231
COMPONENT PARTS OF ELECTRICAL SYSTEM231
ALTERNATOR231
STARTING MOTOR234
ENGINE WIRING HARNESS237
ENGINE CONTROLLER239
SENSOR246
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 SENSOR249
FUNCTION OF AMBIENT PRESSURE SENSOR249
STRUCTURE OF ENGINE OIL PRESSURE SWITCH250
FUNCTION OF ENGINE OIL PRESSURE SWITCH250
STRUCTURE OF CHARGE (BOOST) PRESSURE AND TEMPERATURE SENSOR251
FUNCTION OF CHARGE (BOOST) PRESSURE AND TEMPERATURE SENSOR251
STRUCTURE OF COOLANT TEMPERATURE SENSOR252
FUNCTION OF COOLANT TEMPERATURE SENSOR252
STRUCTURE OF NE (CRANKSHAFT) SPEED SENSOR253
FUNCTION OF NE (CRANKSHAFT) SPEED SENSOR253
STRUCTURE OF Bkup (CAMSHAFT) SPEED SENSOR253
FUNCTION OF Bkup (CAMSHAFT) SPEED SENSOR254
STRUCTURE OF COMMON RAIL PRESSURE SENSOR255
FUNCTION OF COMMON RAIL PRESSURE SENSOR255
STRUCTURE OF MASS AIR FLOW AND TEMPERATURE SENSOR256
FUNCTION OF MASS AIR FLOW AND TEMPERATURE SENSOR256
STRUCTURE OF KDPF DIFFERENTIAL PRESSURE AND OUTLET PRESSURE SENSOR257
FUNCTION OF KDPF DIFFERENTIAL PRESSURE AND OUTLET PRESSURE SENSOR257
STRUCTURE OF CRANKCASE PRESSURE SENSOR258
FUNCTION OF CRANKCASE PRESSURE SENSOR258
STRUCTURE OF ENGINE OIL LEVEL SENSOR259
FUNCTION OF ENGINE OIL LEVEL SENSOR259
STRUCTURE OF AIR CLEANER CLOGGING SENSOR260
FUNCTION OF AIR CLEANER CLOGGING SENSOR260
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 TABLE265
CONTENTS266
ABBREVIATION LIST267
STANDARD VALUE TABLE FOR ENGINE273
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, PC130LC-11)275
STANDARD VALUE TABLE FOR ENGINE: SAA4D95LE-7 (PC138US-11, PC138USLC-11, PC138US-11E0)277
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD279
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, PC130LC-11)283
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA4D95LE-7 (PC138US-11, PC138USLC-11, PC138US-11E0)285
50 DISASSEMBLY AND ASSEMBLY287
CONTENTS288
ABBREVIATION LIST289
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY295
HOW TO READ THIS MANUAL295
COATING MATERIALS LIST297
SPECIAL TOOLS LIST302
SKETCHES OF SPECIAL TOOLS304
ENGINE SYSTEM306
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY306
DISASSEMBLE ENGINE GENERALLY307
ASSEMBLE ENGINE GENERALLY333
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY372
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY372
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY375
REMOVE AND INSTALL ENGINE FRONT OIL SEAL378
METHOD FOR REMOVING ENGINE FRONT OIL SEAL378
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL379
REMOVE AND INSTALL ENGINE REAR OIL SEAL381
METHOD FOR REMOVING ENGINE REAR OIL SEAL381
METHOD FOR INSTALLING ENGINE REAR OIL SEAL382
60 MAINTENANCE STANDARD385
CONTENTS386
ABBREVIATION LIST387
ENGINE SYSTEM393
INTAKE AND EXHAUST SYSTEM PARTS393
MAINTENANCE STANDARD OF VARIABLE FLOW TURBOCHARGER393
ENGINE MAIN BODY PARTS394
MAINTENANCE STANDARD OF CYLINDER HEAD394
MAINTENANCE STANDARD OF CYLINDER BLOCK396
MAINTENANCE STANDARD OF CRANKSHAFT399
MAINTENANCE STANDARD OF PISTON401
MAINTENANCE STANDARD OF CONROD403
MAINTENANCE STANDARD OF TIMING GEAR405
MAINTENANCE STANDARD OF CAMSHAFT406
MAINTENANCE STANDARD OF VALVE AND VALVE GUIDE408
MAINTENANCE STANDARD OF ROCKER ARM410
MAINTENANCE STANDARD OF TAPPET412
MAINTENANCE STANDARD OF FLYWHEEL413
LUBRICATION SYSTEM415
MAINTENANCE STANDARD OF ENGINE OIL PUMP415
COOLING SYSTEM417
MAINTENANCE STANDARD OF WATER PUMP417
INDEX419

IMAGES PREVIEW OF THE MANUAL:

S.M 24/12/24