Komatsu 95E-5 Series Engine Shop Manual SEN01966-11 – PDF DOWNLOAD

Komatsu 95E-5 Series Engine Shop Manual SEN01966-11 – PDF DOWNLOAD

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Komatsu 95E-5 Series Engine Shop Manual SEN01966-11 – PDF DOWNLOAD

Language : English
Pages : 46
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TABLE OF CONTENTS:

Komatsu 95E-5 Series Engine Shop Manual SEN01966-11 – PDF DOWNLOAD

00 Index and foreword
Index SEN02121-11
Composition of shop manual…………………………………………………………………………………………. 2
Table of contents …………………………………………………………………………………………………………. 3
Foreword and general information SEN02122-02
Safety notice ………………………………………………………………………………………………………………. 2
How to read the shop manual ……………………………………………………………………………………….. 7
Explanation of terms for maintenance standard……………………………………………………………….. 9
Handling of electric equipment and hydraulic component………………………………………………….. 11
Handling of connectors newly used for engines……………………………………………………………….. 20
How to read electric wire code ………………………………………………………………………………………. 23
Precautions when carrying out operation………………………………………………………………………… 26
Method of disassembling and connecting push-pull type coupler……………………………………….. 29
Standard tightening torque table ……………………………………………………………………………………. 32
Conversion table …………………………………………………………………………………………………………. 36
01 Specification
Specification and technical data SEN02124-06
Outline……………………………………………………………………………………………………………………….. 2
Specifications ……………………………………………………………………………………………………………… 4
General view ………………………………………………………………………………………………………………. 10
Weight table ……………………………………………………………………………………………………………….. 17
Engine performance curves ………………………………………………………………………………………….. 18
10 Structure, function and maintenance standard
Structure, function and maintenance standard, Part 1 SEN02126-08
General structure ………………………………………………………………………………………………………… 4
Air intake and exhaust unit……………………………………………………………………………………………. 6
Air cleaner ………………………………………………………………………………………………………………….. 8
Turbocharger………………………………………………………………………………………………………………. 10
Muffler ……………………………………………………………………………………………………………………….. 13
Cylinder head ……………………………………………………………………………………………………………… 14
Cylinder block……………………………………………………………………………………………………………… 16
Cylinder ……………………………………………………………………………………………………………………… 19
Main moving parts……………………………………………………………………………………………………….. 20
Crankshaft………………………………………………………………………………………………………………….. 22
Camshaft……………………………………………………………………………………………………………………. 23
Piston, piston ring and piston pin …………………………………………………………………………………… 24
Connecting rod……………………………………………………………………………………………………………. 25
Flywheel and flywheel housing ……………………………………………………………………………………… 26
Timing gear ………………………………………………………………………………………………………………… 28
Valve system………………………………………………………………………………………………………………. 32
Valve, valve guide ……………………………………………………………………………………………………….. 34
Rocker arm shaft, push rod and tappet …………………………………………………………………………… 35
Structure, function and maintenance standard, Part 2 SEN02127-05
Lubrication system diagram ………………………………………………………………………………………….. 3
Oil pump…………………………………………………………………………………………………………………….. 4
Regulator valve …………………………………………………………………………………………………………… 6
Oil filter ………………………………………………………………………………………………………………………. 7
Fuel system diagram……………………………………………………………………………………………………. 9
Supply pump ………………………………………………………………………………………………………………. 10
Fuel injection nozzle…………………………………………………………………………………………………….. 12
Fuel filter ……………………………………………………………………………………………………………………. 13
Common rail……………………………………………………………………………………………………………….. 14
Various sensor ……………………………………………………………………………………………………………. 16
SEN02121-11 00 Index and foreword
4 95E-5 Series
Cooling system diagram……………………………………………………………………………………………….. 18
Water pump………………………………………………………………………………………………………………… 19
Cooling fan drive and thermostat …………………………………………………………………………………… 22
Starting and charging system electrical circuit diagram …………………………………………………….. 26
Alternator……………………………………………………………………………………………………………………. 27
Starting motor ……………………………………………………………………………………………………………… 29
Starting aid …………………………………………………………………………………………………………………. 31
Engine controller …………………………………………………………………………………………………………. 32
20 Standard value table
Standard service value table SEN02129-06
Standard service value table for testing, adjusting, and troubleshooting ……………………………… 2
Running-in standard and performance test standard ………………………………………………………… 7
30 Testing and adjusting
Testing and adjusting SEN02182-03
Testing and adjusting tools list……………………………………………………………………………………….. 3
Sketches of special tools………………………………………………………………………………………………. 5
Measuring intake air pressure ……………………………………………………………………………………….. 6
Testing exhaust temperature …………………………………………………………………………………………. 7
Adjusting valve clearance……………………………………………………………………………………………… 8
Testing compression pressure……………………………………………………………………………………….. 10
Testing blow-by pressure………………………………………………………………………………………………. 12
Testing oil pressure ……………………………………………………………………………………………………… 13
Handling fuel system parts ……………………………………………………………………………………………. 14
Releasing residual pressure in fuel system……………………………………………………………………… 14
Testing fuel pressure ……………………………………………………………………………………………………. 15
Reduced cylinder mode operation………………………………………………………………………………….. 16
No-injection cranking……………………………………………………………………………………………………. 16
Testing leakage from pressure limiter and return rate from injector …………………………………….. 17
Bleeding air from fuel circuit ………………………………………………………………………………………….. 20
Testing fuel system for leakage ……………………………………………………………………………………… 22
Testing and adjusting alternator belt tension ……………………………………………………………………. 23
Handling controller voltage circuit ………………………………………………………………………………….. 24
40 Troubleshooting
General information on troubleshooting SEN02183-02
Points on troubleshooting……………………………………………………………………………………………… 2
Error code and failure code table …………………………………………………………………………………… 4
Information in troubleshooting table ……………………………………………………………………………….. 6
Connection table for connector pin numbers……………………………………………………………………. 8
T- branch box and T- branch adapter table ……………………………………………………………………… 44
Troubleshooting of electrical system (E-mode), Part 1 SEN02185-01
E-1 Code [111/CA111] ECM Critical Internal Failure …………………………………………………………. 4
E-2 Code [115/CA115] Eng. Ne and Bkup Speed Sensor Error ………………………………………….. 7
E-3 Code [122/CA122] Charge Air Press Sensor High Error ……………………………………………… 8
E-4 Code [123/CA123] Charge Air Press Sensor Low Error………………………………………………. 10
E-5 Code [131/CA131] Throttle Sensor High Error …………………………………………………………… 11
E-6 Code [132/CA132] Throttle Sensor Low Error ……………………………………………………………. 14
E-7 Code [144/CA144] Coolant Temp. Sensor High Error …………………………………………………. 16
E-8 Code [145/CA145] Coolant Temp. Sensor Low Error ………………………………………………….. 18
E-9 Code [153/CA153] Charge Air Temp. Sensor High Error …………………………………………….. 20
E-10 Code [154/CA154] Charge Air Temp. Sensor Low Error ……………………………………………. 22
E-11 Code [187/CA187] Sensor Sup. 2 Volt. Low Error …………………………………………………….. 23
E-12 Code [221/CA221] Ambient Air Press. Sensor High Error………………………………………….. 24
E-13 Code [222/CA222] Ambient Air Press. Sensor Low Error ………………………………………….. 26
E-14 Code [227/CA227] Sensor Sup. 2 Volt. High Error ……………………………………………………. 27
00 Index and foreword SEN02121-11
95E-5 Series 5
E-15 Code [234/CA234] Eng. Overspeed ……………………………………………………………………….. 28
E-16 Code [238/CA238] Ne Speed Sensor Sup. Volt. Error ………………………………………………. 30
E-17 Code [271/CA271] IMV Short Error ………………………………………………………………………… 32
E-18 Code [272/CA272] IMV Open Error………………………………………………………………………… 34
E-19 Code [322/CA322] Injector #1 System Open/Short Error…………………………………………… 36
E-20 Code [324/CA324] Injector #3 System Open/Short Error…………………………………………… 38
E-21 Code [331/CA331] Injector #2 System Open/Short Error…………………………………………… 40
E-22 Code [332/CA332] Injector #4 System Open/Short Error…………………………………………… 42
E-23 Code [351/CA351] INJ. Drive Circuit Error ………………………………………………………………. 44
E-24 Code [352/CA352] Sensor Sup. 1 Volt. Low Error…………………………………………………….. 47
E-25 Code [386/CA386] Sensor Sup. 1 Volt. High Error……………………………………………………. 48
E-26 Code [431/CA431] Idle Validation SW Low error………………………………………………………. 50
E-27 Code [432/CA432] Idle Validation Process error ………………………………………………………. 50
E-28 Code [435/CA435] Abnormality in engine oil pressure switch…………………………………….. 51
E-29 Code [441/CA441] Battery voltage low error ……………………………………………………………. 52
E-30 Code [442/CA442] Battery voltage high error…………………………………………………………… 52
Troubleshooting of electrical system (E-mode), Part 2 SEN02186-01
E-31 Code [449/CA449] Rail Press. Very High Error ………………………………………………………… 3
E-32 Code [451/CA451] Rail Press. Sensor High Error…………………………………………………….. 4
E-33 Code [452/CA452] Rail Press. Sensor Low Error……………………………………………………… 6
E-34 Code [553/CA553] Rail Press. High Error ……………………………………………………………….. 7
E-35 Code [559/CA559] Rail Press. Low Error ………………………………………………………………… 8
E-36 Code [689/CA689] Eng. Ne Speed Sensor Error ……………………………………………………… 12
E-37 Code [731/CA731] Eng. Bkup Speed Sensor Phase Error…………………………………………. 14
E-38 Code [757/CA757] All Persistent Data Lost Error……………………………………………………… 15
E-39 Code [778/CA778] Eng. Bkup Speed Sensor Error…………………………………………………… 16
E-40 Code [1633/CA1633] KOMNET Dtalink Timeout Error………………………………………………. 18
E-41 Code [2185/CA2185] Throttle Sens. Sup. Volt. High Error…………………………………………. 19
E-42 Code [2186/CA2186] Throttle Sens. Sup. Volt. Low Error………………………………………….. 22
E-43 Code [2249/CA2249] Rail Press. Very Low Error……………………………………………………… 23
E-44 Code [2311/CA2311] Abnormality in IMV solenoid ……………………………………………………. 24
E-45 Code [2555/CA2555] Grid Heater Relay Volt. Low Error……………………………………………. 26
E-46 Code [2556/CA2556] Grid Heater Relay Volt. High Error…………………………………………… 28
E-47 Code [(—)/B@BAZG] Eng. Oil press. Low Speed Derate …………………………………………. 30
E-48 Code [(—)/B@BAZG] Eng. Oil press. Torque Derate ……………………………………………….. 30
E-49 Code [(—)/B@BCNS] Eng. Overheat …………………………………………………………………….. 31
Troubleshooting of mechanical system (S-mode) SEN02184-02
Method of using troubleshooting charts ………………………………………………………………………….. 4
S-1 Starting performance is poor …………………………………………………………………………………… 8
S-2 Engine does not start……………………………………………………………………………………………… 9
S-3 Engine does not pick up smoothly……………………………………………………………………………. 12
S-4 Engine stops during operations ……………………………………………………………………………….. 13
S-5 Engine does not rotate smoothly ……………………………………………………………………………… 14
S-6 Engine lacks output (or lacks power)………………………………………………………………………… 15
S-7 Exhaust smoke is black (incomplete combustion)………………………………………………………. 16
S-8 Oil consumption is excessive (or exhaust smoke is blue) ……………………………………………. 17
S-9 Oil becomes contaminated quickly …………………………………………………………………………… 18
S-10 Fuel consumption is excessive………………………………………………………………………………. 19
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) …………………………… 20
S-12 Oil pressure drops ……………………………………………………………………………………………….. 21
S-13 Oil level rises (Entry of coolant or fuel)……………………………………………………………………. 22
S-14 Coolant temperature becomes too high (overheating) ………………………………………………. 23
S-15 Abnormal noise is made ……………………………………………………………………………………….. 24
S-16 Vibration is excessive …………………………………………………………………………………………… 25
SEN02121-11 00 Index and foreword
6 95E-5 Series
50 Disassembly and assembly
General information on disassembly and assembly SEN02187-02
How to read this manual……………………………………………………………………………………………….. 2
Coating materials list ……………………………………………………………………………………………………. 3
Special tools list…………………………………………………………………………………………………………… 6
Sketches of special tools………………………………………………………………………………………………. 7
Disassembly and assembly, Part 1 SEN02188-00
General disassembly of engine ……………………………………………………………………………………… 2
Disassembly and assembly, Part 2 SEN02189-02
General assembly of engine………………………………………………………………………………………….. 2
Disassembly and assembly, Part 3 SEN02190-00
Disassembly and assembly procedure for fuel supply pump unit ……………………………………….. 2
Disassembly and assembly procedure for oil seal units…………………………………………………….. 4
90 Repair and replacement of parts
Information related to repair and replacement SEN05207-00
Special tool table …………………………………………………………………………………………………………. 2
Sketches of special tools………………………………………………………………………………………………. 4
Parts related to cylinder head SEN05208-00
Part names related to cylinder head……………………………………………………………………………….. 2
Testing and inspection of cylinder head ………………………………………………………………………….. 3
Pressure test of cylinder head……………………………………………………………………………………….. 5
Replacement of valve guide ………………………………………………………………………………………….. 5
Replacement of valve seat insert …………………………………………………………………………………… 7
Repair of cylinder head mounting face by grinding …………………………………………………………… 13
Repair of valve by grinding……………………………………………………………………………………………. 14
Parts related to cylinder block SEN05209-00
Part names related to cylinder block ………………………………………………………………………………. 2
Testing and inspection of cylinder block ………………………………………………………………………….. 3
Part names related to crankshaft …………………………………………………………………………………… 6
Testing and inspection of crankshaft ………………………………………………………………………………. 7
Part names related to connecting rod …………………………………………………………………………….. 8
Testing and inspection of connecting rod ………………………………………………………………………… 9
Replacement of flywheel ring gear …………………………………………………………………………………. 10
Replacement of crankshaft gear ……………………………………………………………………………………. 11
Replacement of camshaft gear ……………………………………………………………………………………… 11
Replacement of connecting rod small end bushing…………………………………………………………… 12
Replacement of cam bushing………………………………………………………………………………………… 14
Cylinder liner (Special part for repair)……………………………………………………………………………… 16
Rework drawing for counter bore …………………………………………………………………………………… 17
Repair of crankshaft by grinding…………………………………………………………………………………….. 18