Komatsu 95E-5 Series Engine Shop Manual SEN01966-16 – PDF DOWNLOAD

Komatsu 95E-5 Series Engine Shop Manual SEN01966-16 – PDF DOWNLOAD

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Komatsu 95E-5 Series Engine Shop Manual SEN01966-16 – PDF DOWNLOAD

Language : English
Pages : 448
Downloadable : Yes
File Type : PDF
Size: 18.4 MB

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Komatsu 95E-5 Series Engine Shop Manual SEN01966-16 – PDF DOWNLOAD

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)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
This section explains the method of reproducing, repairing, and replacing parts.

TABLE OF CONTENTS:

Komatsu 95E-5 Series Engine Shop Manual SEN01966-16 – PDF DOWNLOAD

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………………………………………………………… 73
Engine performance curves…………………………………………….. 74
10 Structure, function and maintenance standard………………………………… 0
Structure, function and maintenance standard, Part 1………………………… 83
General structure……………………………………………………. 86
Air intake and exhaust unit…………………………………………… 88
Air cleaner…………………………………………………………. 90
Turbocharger………………………………………………………… 92
Muffler…………………………………………………………….. 95
Cylinder head……………………………………………………….. 96
Cylinder block………………………………………………………. 98
Cylinder…………………………………………………………….101
Main moving parts…………………………………………………….102
Crankshaft…………………………………………………………..104
Camshaft…………………………………………………………….105
Piston, piston ring and piston pin……………………………………..106
Connecting rod……………………………………………………….107
Flywheel and flywheel housing………………………………………….110
Timing gear………………………………………………………….112
Valve system…………………………………………………………116
Valve, valve guide……………………………………………………118
Rocker arm shaft, push rod and tappet…………………………………..119
Structure, function and maintenance standard, Part 2…………………………121
Lubrication system diagram…………………………………………….123
Oil pump…………………………………………………………….124
Regulator valve………………………………………………………126
Oil filter…………………………………………………………..127
Fuel system diagram…………………………………………………..129
Supply pump………………………………………………………….130
Fuel injection nozzle…………………………………………………132
Fuel filter………………………………………………………….133
Common rail………………………………………………………….134
Various sensor……………………………………………………….136
Cooling system diagram………………………………………………..138
Water pump…………………………………………………………..139
Cooling fan drive and thermostat……………………………………….142
Starting and charging system electrical circuit diagram…………………..146
Alternator…………………………………………………………..147
Starting motor……………………………………………………….151
Starting aid…………………………………………………………153
Engine controller…………………………………………………….154
20 Standard value table……………………………………………………… 0
Standard service value table………………………………………………157
Standard service value table for testing, adjusting, and troubleshooting……158
Running-in standard and performance test standard………………………..164
30 Testing and adjusting…………………………………………………….. 0
Testing and adjusting…………………………………………………….173
Testing and adjusting tools list……………………………………….175
Sketches of special tools……………………………………………..177
Measuring intake air pressure………………………………………….178
Testing exhaust temperature……………………………………………179
Adjusting valve clearance……………………………………………..180
Testing compression pressure…………………………………………..182
Testing blow-by pressure………………………………………………184
Testing oil pressure………………………………………………….185
Handling fuel system parts…………………………………………….186
Releasing residual pressure in fuel system………………………………186
Testing fuel pressure…………………………………………………187
Reduced cylinder mode operation………………………………………..188
No-injection cranking…………………………………………………188
Testing leakage from pressure limiter and return rate from injector………..189
Bleeding air from fuel circuit…………………………………………192
Testing fuel system for leakage………………………………………..194
Testing and adjusting alternator belt tension……………………………195
Handling controller voltage circuit…………………………………….196
40 Troubleshooting………………………………………………………….. 0
General information on troubleshooting……………………………………..199
Points on troubleshooting……………………………………………..200
Error code and failure code table………………………………………202
Information in troubleshooting table……………………………………204
Connection table for connector pin numbers………………………………206
T- branch box and T- branch adapter table……………………………….242
Troubleshooting of electrical system (E-mode), Part 1………………………..247
E-1 Code [111/CA111] ECM Critical Internal Failure……………………….250
E-2 Code [115/CA115] Eng. Ne and Bkup Speed Sensor Error………………….253
E-3 Code [122/CA122] Charge Air Press Sensor High Error…………………..254
E-4 Code [123/CA123] Charge Air Press Sensor Low Error……………………256
E-5 Code [131/CA131] Throttle Sensor High Error………………………….257
E-6 Code [132/CA132] Throttle Sensor Low Error…………………………..260
E-7 Code [144/CA144] Coolant Temp. Sensor High Error……………………..262
E-8 Code [145/CA145] Coolant Temp. Sensor Low Error………………………264
E-9 Code [153/CA153] Charge Air Temp. Sensor High Error…………………..266
E-10 Code [154/CA154] Charge Air Temp. Sensor Low Error…………………..268
E-11 Code [187/CA187] Sensor Sup. 2 Volt. Low Error………………………269
E-12 Code [221/CA221] Ambient Air Press. Sensor High Error………………..270
E-13 Code [222/CA222] Ambient Air Press. Sensor Low Error…………………272
E-14 Code [227/CA227] Sensor Sup. 2 Volt. High Error……………………..273
E-15 Code [234/CA234] Eng. Overspeed……………………………………274
E-16 Code [238/CA238] Ne Speed Sensor Sup. Volt. Error……………………276
E-17 Code [271/CA271] IMV Short Error…………………………………..278
E-18 Code [272/CA272] IMV Open Error……………………………………280
E-19 Code [322/CA322] Injector #1 System Open/Short Error…………………282
E-20 Code [324/CA324] Injector #3 System Open/Short Error…………………284
E-21 Code [331/CA331] Injector #2 System Open/Short Error…………………286
E-22 Code [332/CA332] Injector #4 System Open/Short Error…………………288
E-23 Code [351/CA351] INJ. Drive Circuit Error…………………………..290
E-24 Code [352/CA352] Sensor Sup. 1 Volt. Low Error………………………293
E-25 Code [386/CA386] Sensor Sup. 1 Volt. High Error……………………..294
E-26 Code [431/CA431] Idle Validation SW Low error……………………….296
E-27 Code [432/CA432] Idle Validation Process error………………………296
E-28 Code [435/CA435] Abnormality in engine oil pressure switch……………297
E-29 Code [441/CA441] Battery voltage low error………………………….298
E-30 Code [442/CA442] Battery voltage high error…………………………298
Troubleshooting of electrical system (E-mode), Part 2………………………..301
E-31 Code [449/CA449] Rail Press. Very High Error………………………..303
E-32 Code [451/CA451] Rail Press. Sensor High Error………………………304
E-33 Code [452/CA452] Rail Press. Sensor Low Error……………………….306
E-34 Code [553/CA553] Rail Press. High Error…………………………….307
E-35 Code [559/CA559] Rail Press. Low Error……………………………..308
E-36 Code [689/CA689] Eng. Ne Speed Sensor Error…………………………312
E-37 Code [731/CA731] Eng. Bkup Speed Sensor Phase Error………………….314
E-38 Code [757/CA757] All Persistent Data Lost Error……………………..315
E-39 Code [778/CA778] Eng. Bkup Speed Sensor Error……………………….316
E-40 Code [1633/CA1633] KOMNET Dtalink Timeout Error……………………..318
E-41 Code [2185/CA2185] Throttle Sens. Sup. Volt. High Error………………319
E-42 Code [2186/CA2186] Throttle Sens. Sup. Volt. Low Error……………….322
E-43 Code [2249/CA2249] Rail Press. Very Low Error……………………….323
E-44 Code [2311/CA2311] Abnormality in IMV solenoid………………………324
E-45 Code [2555/CA2555] Grid Heater Relay Volt. Low Error…………………325
E-46 Code [2556/CA2556] Grid Heater Relay Volt. High Error………………..326
E-47 Code [(—)/B@BAZG] Eng. Oil press. Low Speed Derate…………………328
E-48 Code [(—)/B@BAZG] Eng. Oil press. Torque Derate……………………328
E-49 Code [(—)/B@BCNS] Eng. Overheat………………………………….329
Troubleshooting of mechanical system (S-mode)……………………………….331
Method of using troubleshooting charts………………………………….334
S-1 Starting performance is poor……………………………………….338
S-2 Engine does not start……………………………………………..339
S-3 Engine does not pick up smoothly……………………………………342
S-4 Engine stops during operations……………………………………..343
S-5 Engine does not rotate smoothly…………………………………….344
S-6 Engine lacks output (or lacks power)………………………………..345
S-7 Exhaust smoke is black (incomplete combustion)……………………….346
S-8 Oil consumption is excessive (or exhaust smoke is blue)……………….347
S-9 Oil becomes contaminated quickly……………………………………348
S-10 Fuel consumption is excessive……………………………………..349
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)….350
S-12 Oil pressure drops……………………………………………….351
S-13 Oil level rises (Entry of coolant or fuel)………………………….352
S-14 Coolant temperature becomes too high (overheating)…………………..353
S-15 Abnormal noise is made……………………………………………354
S-16 Vibration is excessive……………………………………………355
50 Disassembly and assembly………………………………………………….. 0
General information on disassembly and assembly……………………………..357
How to read this manual……………………………………………….358
Coating materials list………………………………………………..360
Special tools list……………………………………………………363
Sketches of special tools……………………………………………..364
Disassembly and assembly, Part 1…………………………………………..367
General disassembly of engine………………………………………….368
Disassembly and assembly, Part 2…………………………………………..381
General assembly of engine…………………………………………….382
Disassembly and assembly, Part 3…………………………………………..399
Disassembly and assembly procedure for fuel supply pump unit………………400
Disassembly and assembly procedure for oil seal units…………………….402
90 Repair and replacement of parts……………………………………………. 0
Information related to repair and replacement……………………………….405
Special tool table……………………………………………………406
Sketches of special tools……………………………………………..408
Parts related to cylinder head…………………………………………….411
Part names related to cylinder head…………………………………….412
Testing and inspection of cylinder head…………………………………413
Pressure test of cylinder head…………………………………………415
Replacement of valve guide…………………………………………….415
Replacement of valve seat insert……………………………………….417
Repair of cylinder head mounting face by grinding………………………..423
Repair of valve by grinding……………………………………………424
Parts related to cylinder block……………………………………………427
Part names related to cylinder block……………………………………428
Testing and inspection of cylinder block………………………………..429
Part names related to crankshaft……………………………………….432
Testing and inspection of crankshaft……………………………………433
Part names related to connecting rod……………………………………434
Testing and inspection of connecting rod………………………………..435
Replacement of flywheel ring gear………………………………………436
Replacement of crankshaft gear…………………………………………437
Replacement of camshaft gear…………………………………………..437
Replacement of connecting rod small end bushing………………………….438
Replacement of cam bushing…………………………………………….440
Cylinder liner (Special part for repair)………………………………..442
Rework drawing for counter bore………………………………………..443
Repair of crankshaft by grinding……………………………………….444