Complete service repair manual with Electrical Wiring Diagrams for Komatsu 95E Series Diesel Engines, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu 95E Series Diesel Engines workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
SEN01966-15 – 95E-5 Series Diesel Engine Shop Manual.pdf
SEN04357-00 – 95E-5 Series (KOHAG SPEC.) Diesel Engine Shop Manual.pdf
SEN06060-01 – 95E-6 Series Diesel Engine Shop Manual.pdf
Total Pages: 1,041 pages
File Format: PDF
Language: English
MAIN SECTIONS
01 GENERAL ……. 01-1
11 STRUCTURE AND FUNCTION …. 11-1
12 TESTING AND ADJUSTING ….. 12-1
13 DISASSEMBLY AND ASSEMBLY …. 13-1
14 MAINTENANCE STANDARD ….. 14-1
15 REPAIR AND REPLACEMENT OF PARTS … 15-1
SEN01966-15 – 95E-5 Series Diesel Engine Shop Manual……2
COVER……2
00 Index and foreword……0
Index……4
Composition of shop manual……5
Table of contents……6
Foreword and general information……12
Safety notice……13
How to read the shop manual……18
Explanation of terms for maintenance standard……20
Handling of electric equipment and hydraulic component……22
Handling of connectors newly used for engines……31
How to read electric wire code……34
Precautions when carrying out operation……37
Method of disassembling and connecting push-pull type coupler……40
Standard tightening torque table……43
Conversion table……47
01 Specification……0
Specification and technical data……54
General information……55
Specifications……57
General view……65
Weight table……74
Engine performance curves……75
10 Structure, function and maintenance standard……0
Structure, function and maintenance standard, Part 1……84
General structure……87
Air intake and exhaust unit……89
Air cleaner……91
Turbocharger……93
Muffler……96
Cylinder head……97
Cylinder block……99
Cylinder……102
Main moving parts……103
Crankshaft……105
Camshaft……106
Piston, piston ring and piston pin……107
Connecting rod……108
Flywheel and flywheel housing……111
Timing gear……113
Valve system……117
Valve, valve guide……119
Rocker arm shaft, push rod and tappet……120
Structure, function and maintenance standard, Part 2……122
Lubrication system diagram……124
Oil pump……125
Regulator valve……127
Oil filter……128
Fuel system diagram……130
Supply pump……131
Fuel injection nozzle……133
Fuel filter……134
Common rail……135
Various sensor……137
Cooling system diagram……139
Water pump……140
Cooling fan drive and thermostat……143
Starting and charging system electrical circuit diagram……147
Alternator……148
Starting motor……152
Starting aid……154
Engine controller……155
20 Standard value table……0
Standard service value table……158
Standard service value table for testing, adjusting, and troubleshooting……159
Running-in standard and performance test standard……165
30 Testing and adjusting……0
Testing and adjusting……174
Testing and adjusting tools list……176
Sketches of special tools……178
Measuring intake air pressure……179
Testing exhaust temperature……180
Adjusting valve clearance……181
Testing compression pressure……183
Testing blow-by pressure……185
Testing oil pressure……186
Handling fuel system parts……187
Releasing residual pressure in fuel system……187
Testing fuel pressure……188
Reduced cylinder mode operation……189
No-injection cranking……189
Testing leakage from pressure limiter and return rate from injector……190
Bleeding air from fuel circuit……193
Testing fuel system for leakage……195
Testing and adjusting alternator belt tension……196
Handling controller voltage circuit……197
40 Troubleshooting……0
General information on troubleshooting……200
Points on troubleshooting……201
Error code and failure code table……203
Information in troubleshooting table……205
Connection table for connector pin numbers……207
T- branch box and T- branch adapter table……243
Troubleshooting of electrical system (E-mode), Part 1……248
E-1 Code [111/CA111] ECM Critical Internal Failure……251
E-2 Code [115/CA115] Eng. Ne and Bkup Speed Sensor Error……254
E-3 Code [122/CA122] Charge Air Press Sensor High Error……255
E-4 Code [123/CA123] Charge Air Press Sensor Low Error……257
E-5 Code [131/CA131] Throttle Sensor High Error……258
E-6 Code [132/CA132] Throttle Sensor Low Error……261
E-7 Code [144/CA144] Coolant Temp. Sensor High Error……263
E-8 Code [145/CA145] Coolant Temp. Sensor Low Error……265
E-9 Code [153/CA153] Charge Air Temp. Sensor High Error……267
E-10 Code [154/CA154] Charge Air Temp. Sensor Low Error……269
E-11 Code [187/CA187] Sensor Sup. 2 Volt. Low Error……270
E-12 Code [221/CA221] Ambient Air Press. Sensor High Error……271
E-13 Code [222/CA222] Ambient Air Press. Sensor Low Error……273
E-14 Code [227/CA227] Sensor Sup. 2 Volt. High Error……274
E-15 Code [234/CA234] Eng. Overspeed……275
E-16 Code [238/CA238] Ne Speed Sensor Sup. Volt. Error……277
E-17 Code [271/CA271] IMV Short Error……279
E-18 Code [272/CA272] IMV Open Error……281
E-19 Code [322/CA322] Injector #1 System Open/Short Error……283
E-20 Code [324/CA324] Injector #3 System Open/Short Error……285
E-21 Code [331/CA331] Injector #2 System Open/Short Error……287
E-22 Code [332/CA332] Injector #4 System Open/Short Error……289
E-23 Code [351/CA351] INJ. Drive Circuit Error……291
E-24 Code [352/CA352] Sensor Sup. 1 Volt. Low Error……294
E-25 Code [386/CA386] Sensor Sup. 1 Volt. High Error……295
E-26 Code [431/CA431] Idle Validation SW Low error……297
E-27 Code [432/CA432] Idle Validation Process error……297
E-28 Code [435/CA435] Abnormality in engine oil pressure switch……298
E-29 Code [441/CA441] Battery voltage low error……299
E-30 Code [442/CA442] Battery voltage high error……299
Troubleshooting of electrical system (E-mode), Part 2……302
E-31 Code [449/CA449] Rail Press. Very High Error……304
E-32 Code [451/CA451] Rail Press. Sensor High Error……305
E-33 Code [452/CA452] Rail Press. Sensor Low Error……307
E-34 Code [553/CA553] Rail Press. High Error……308
E-35 Code [559/CA559] Rail Press. Low Error……309
E-36 Code [689/CA689] Eng. Ne Speed Sensor Error……313
E-37 Code [731/CA731] Eng. Bkup Speed Sensor Phase Error……315
E-38 Code [757/CA757] All Persistent Data Lost Error……316
E-39 Code [778/CA778] Eng. Bkup Speed Sensor Error……317
E-40 Code [1633/CA1633] KOMNET Dtalink Timeout Error……319
E-41 Code [2185/CA2185] Throttle Sens. Sup. Volt. High Error……320
E-42 Code [2186/CA2186] Throttle Sens. Sup. Volt. Low Error……323
E-43 Code [2249/CA2249] Rail Press. Very Low Error……324
E-44 Code [2311/CA2311] Abnormality in IMV solenoid……325
E-45 Code [2555/CA2555] Grid Heater Relay Volt. Low Error……326
E-46 Code [2556/CA2556] Grid Heater Relay Volt. High Error……327
E-47 Code [(—)/B@BAZG] Eng. Oil press. Low Speed Derate……329
E-48 Code [(—)/B@BAZG] Eng. Oil press. Torque Derate……329
E-49 Code [(—)/B@BCNS] Eng. Overheat……330
Troubleshooting of mechanical system (S-mode)……332
Method of using troubleshooting charts……335
S-1 Starting performance is poor……339
S-2 Engine does not start……340
S-3 Engine does not pick up smoothly……343
S-4 Engine stops during operations……344
S-5 Engine does not rotate smoothly……345
S-6 Engine lacks output (or lacks power)……346
S-7 Exhaust smoke is black (incomplete combustion)……347
S-8 Oil consumption is excessive (or exhaust smoke is blue)……348
S-9 Oil becomes contaminated quickly……349
S-10 Fuel consumption is excessive……350
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)……351
S-12 Oil pressure drops……352
S-13 Oil level rises (Entry of coolant or fuel)……353
S-14 Coolant temperature becomes too high (overheating)……354
S-15 Abnormal noise is made……355
S-16 Vibration is excessive……356
50 Disassembly and assembly……0
General information on disassembly and assembly……358
How to read this manual……359
Coating materials list……361
Special tools list……364
Sketches of special tools……365
Disassembly and assembly, Part 1……368
General disassembly of engine……369
Disassembly and assembly, Part 2……382
General assembly of engine……383
Disassembly and assembly, Part 3……400
Disassembly and assembly procedure for fuel supply pump unit……401
Disassembly and assembly procedure for oil seal units……403
90 Repair and replacement of parts……0
Information related to repair and replacement……406
Special tool table……407
Sketches of special tools……409
Parts related to cylinder head……412
Part names related to cylinder head……413
Testing and inspection of cylinder head……414
Pressure test of cylinder head……416
Replacement of valve guide……416
Replacement of valve seat insert……418
Repair of cylinder head mounting face by grinding……424
Repair of valve by grinding……425
Parts related to cylinder block……428
Part names related to cylinder block……429
Testing and inspection of cylinder block……430
Part names related to crankshaft……433
Testing and inspection of crankshaft……434
Part names related to connecting rod……435
Testing and inspection of connecting rod……436
Replacement of flywheel ring gear……437
Replacement of crankshaft gear……438
Replacement of camshaft gear……438
Replacement of connecting rod small end bushing……439
Replacement of cam bushing……441
Cylinder liner (Special part for repair)……443
Rework drawing for counter bore……444
Repair of crankshaft by grinding……445
SEN04357-00 – 95E-5 Series (KOHAG SPEC.) Diesel Engine Shop Manual……450
SEN04357-00 WA90-6, WA100M-6……450
00 Index and foreword……452
Index……452
Composition of shop manual……453
Table of contents……454
Foreword and general information……460
Safety notice……461
How to read the shop manual……466
Explanation of terms for maintenance standard……468
Handling of electric equipment and hydraulic component……470
Handling of connectors newly used for engines……479
How to read electric wire code……482
Precautions when carrying out operation……485
Method of disassembling and connecting push-pull type coupler……488
Standard tightening torque table……491
Conversion table……495
01 Specification……502
Specification and technical data……502
Outline……503
Specifications……505
General view……507
Weight table……510
Engine performance curves……511
10 Structure, function and maintenance standard……516
Structure, function and maintenance standard, Part 1……516
General structure……519
Air intake and exhaust system……521
Air intake and exhaust unit……521
Turbocharger……523
Engine unit……527
Cylinder head……527
Cylinder block……529
Cylinder……532
Main moving parts……533
Crankshaft……535
Camshaft……536
Piston, piston ring and piston pin……537
Connecting rod……538
Flywheel and flywheel housing……539
Timing gear……541
Valve system……545
Valve, valve guide……547
Rocker arm shaft, push rod and tappet……548
Structure, function and maintenance standard, Part 2……550
Lubrication system……552
Lubrication system diagram……552
Oil pump……553
Regulator valve……555
Oil filter……556
Fuel system……558
Fuel system diagram……558
Supply pump……559
Fuel injection nozzle……561
Fuel filter……562
Common rail……563
Various sensor……565
Cooling system……567
Cooling system diagram……567
Water pump……568
Cooling fan drive and thermostat……571
Electrical equipment……575
Starting and charging system electrical circuit diagram……575
Alternator……576
Starting motor……578
Starting aid……579
Engine controller……580
20 Standard value table……582
Standard service value table……582
Standard service value table for testing, adjusting, and troubleshooting……583
Running-in standard and performance test standard……584
30 Testing and adjusting……588
Testing and adjusting……588
Testing and adjusting tools list……590
Measuring intake air pressure……591
Testing exhaust temperature……592
Adjusting valve clearance……593
Testing compression pressure……595
Testing blow-by pressure……597
Testing oil pressure……598
Handling fuel system parts……599
Releasing residual pressure in fuel system……599
Testing fuel pressure……600
Reduced cylinder mode operation……601
No-injection cranking……601
Testing leakage from pressure limiter and return rate from injector……602
Bleeding air from fuel circuit……605
Testing fuel system for leakage……607
Testing and adjusting alternator belt tension……608
Handling controller voltage circuit……609
40 Troubleshooting……612
General information on troubleshooting……612
Points on troubleshooting……613
Error code and failure code table……615
Information in troubleshooting table……617
Troubleshooting of electrical system (E-mode), Part 1……620
E-1 Code [111/CA111] ECM Critical Internal Failure……623
E-2 Code [115/CA115] Eng. Ne and Bkup Speed Sensor Error……626
E-3 Code [122/CA122] Charge Air Press Sensor High Error……627
E-4 Code [123/CA123] Charge Air Press Sensor Low Error……629
E-5 Code [131/CA131] Throttle Sensor High Error……630
E-6 Code [132/CA132] Throttle Sensor Low Error……633
E-7 Code [144/CA144] Coolant Temp. Sensor High Error……634
E-8 Code [145/CA145] Coolant Temp. Sensor Low Error……635
E-9 Code [153/CA153] Charge Air Temp. Sensor High Error……637
E-10 Code [154/CA154] Charge Air Temp. Sensor Low Error……639
E-11 Code [187/CA187] Sensor Sup. 2 Volt. Low Error……640
E-12 Code [221/CA221] Ambient Air Press. Sensor High Error……641
E-13 Code [222/CA222] Ambient Air Press. Sensor Low Error……643
E-14 Code [227/CA227] Sensor Sup. 2 Volt. High Error……644
E-15 Code [234/CA234] Eng. Overspeed……646
E-16 Code [238/CA238] Ne Speed Sensor Sup. Volt. Error……647
E-17 Code [271/CA271] IMV Short Error……649
E-18 Code [272/CA272] IMV Open Error……651
E-19 Code [322/CA322] Injector #1 (L/B #1) System Open/Short Error……653
E-20 Code [324/CA324] Injector #3 (L/B #3) System Open/Short Error……655
E-21 Code [331/CA331] Injector #2 (L/B #2) System Open/Short Error……657
E-22 Code [332/CA332] Injector #4 (L/B #4) System Open/Short Error……659
E-23 Code [351/CA351] INJ. Drive Circuit Error……661
E-24 Code [352/CA352] Sensor Sup. 1 Volt. Low Error……664
E-25 Code [386/CA386] Sensor Sup. 1 Volt. High Error……665
E-26 Code [431/CA431] Idle Validation SW Low error……667
E-27 Code [432/CA432] Idle Validation Process error……667
E-28 Code [435/CA435] Abnormality in engine oil pressure switch……668
E-29 Code [441/CA441] Battery voltage low error……669
E-30 Code [442/CA442] Battery voltage high error……669
Troubleshooting of electrical system (E-mode), Part 2……672
E-31 Code [449/CA449] Rail Press. Very High Error……674
E-32 Code [451/CA451] Rail Press. Sensor High Error……675
E-33 Code [452/CA452] Rail Press. Sensor Low Error……677
E-34 Code [553/CA553] Rail Press. High Error……678
E-35 Code [559/CA559] Rail Press. Low Error……679
E-36 Code [689/CA689] Eng. Ne Speed Sensor Error……683
E-37 Code [731/CA731] Eng. Bkup Speed Sensor Phase Error……685
E-38 Code [757/CA757] All Persistent Data Lost Error……686
E-39 Code [778/CA778] Eng. Bkup Speed Sensor Error……687
E-40 Code [1633/CA1633] KOMNET Dtalink Timeout Error……689
E-41 Code [2185/CA2185] Throttle Sens. Sup. Volt. High Error……690
E-42 Code [2186/CA2186] Throttle Sens. Sup. Volt. Low Error……693
E-43 Code [2249/CA2249] Rail Press. Very Low Error……694
E-44 Code [2311/CA2311] Abnormality in IMV solenoid……695
E-45 Code [2555/CA2555] Grid Heater Relay Volt. Low Error……697
E-46 Code [2556/CA2556] Grid Heater Relay Volt. High Error……699
E-47 Code [(- – -)/B@BAZG] Eng. Oil press. Low Speed Derate……701
E-48 Code [(- – -)/B@BAZG] Eng. Oil press. Torque Derate……701
E-49 Code [(- – -)/B@BCNS] Eng. Overheat……702
Troubleshooting of mechanical system (S-mode)……704
Method of using troubleshooting charts……707
S-1 Starting performance is poor……711
S-2 Engine does not start……712
S-3 Engine does not pick up smoothly……715
S-4 Engine stops during operations……716
S-5 Engine does not rotate smoothly……717
S-6 Engine lacks output (or lacks power)……718
S-7 Exhaust smoke is black (incomplete combustion)……719
S-8 Oil consumption is excessive (or exhaust smoke is blue)……720
S-9 Oil becomes contaminated quickly……721
S-10 Fuel consumption is excessive……722
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)……723
S-12 Oil pressure drops……724
S-13 Oil level rises (Entry of coolant or fuel)……725
S-14 Coolant temperature becomes too high (overheating)……726
S-15 Abnormal noise is made……727
S-16 Vibration is excessive……728
50 Disassembly and assembly……730
General information on disassembly and assembly……730
How to read this manual……731
Coating materials list……732
Special tools list……735
Disassembly and assembly, Part 1……738
General disassembly of engine……739
Disassembly and assembly, Part 2……752
General assembly of engine……753
Disassembly and assembly, Part 3……770
Disassembly and assembly procedure for fuel supply pump unit……771
Disassembly and assembly procedure for oil seal units……773
SEN06060-01 – 95E-6 Series Diesel Engine Shop Manual……776
COVER……776
00 Index and foreword ……778
Index ……779
Foreword, safety and general information ……782
Important safety notice ……782
How to read the shop manual ……789
Explanation of terms for maintenance standard ……791
Handling equipment of fuel system devices ……793
Handling of intake system parts ……794
Handling of hydraulic equipment ……795
Method of disconnecting and connecting of push-pull type coupler ……797
Handling of electrical equipment ……800
How to read electric wire code ……808
Precautions when performing operation ……811
Standard tightening torque table ……816
List of abbreviation ……822
Conversion table ……827
01 Specification ……832
Table of contents ……833
General information ……834
Exhaust gas regulation ……834
Specifications ……837
Applicable machines ……837
Specifications ……838
General view ……841
Weight table ……850
Engine performance curve ……851
10 Structure and function ……854
Table of contents ……855
Components layout ……856
Components layout drawing ……856
Intake and exhaust system parts ……858
Intake and exhaust system layout drawing ……858
Intake and exhaust system circuit diagram ……860
Air cleaner ……862
VFT ……863
EGR system piping drawing ……867
EGR system circuit diagram ……869
EGR valve ……870
EGR cooler ……872
KCCV layout drawing ……874
KCCV ventilator ……876
KDOC muffler ……880
Engine main body parts ……882
General structure ……882
Cylinder head ……886
Cylinder block ……888
Main moving parts ……890
Timing gear ……893
Front cover ……895
Valve system ……896
Flywheel and flywheel housing ……898
Lubrication system ……899
Lubrication system chart ……899
Oil pump ……901
Oil filter ……903
Oil cooler ……905
Oil pan ……906
Fuel system ……907
Fuel system parts layout drawing ……907
Fuel system circuit diagram ……909
Prefilter ……910
Main filter ……911
Supply pump ……912
Common rail ……913
Injector ……914
Cooling system ……918
Cooling system parts layout drawing ……918
Cooling system chart ……919
Drive pulley ……920
Water pump ……922
Thermostat and jiggle valve ……923
Electrical equipment ……927
Alternator ……927
Starting motor ……932
Intake air heater ……936
Engine harness ……937
Engine controller ……939
Sensor ……945
20 Standard value tables ……954
Table of contents ……955
Standard service value table ……956
Standard value table for engine ……956
Running-in standard and performance test standard ……960
50 Disassembly and assembly ……964
Table of contents ……965
Related information on disassembly and assembly ……966
How to read this manual ……966
Coating materials list ……968
Special tools list ……972
Sketches of special tools ……973
Disassembly and assembly ……974
General disassembly of engine ……974
General assembly of engine ……989
Removal and installation procedure of supply pump unit alone ……1012
Engine front oil seal replacement procedure ……1015
Engine rear oil seal replacement procedure ……1016
60 Maintenance standard ……1018
Table of contents ……1019
Intake and exhaust system parts ……1020
VFT ……1020
Engine main body parts ……1021
Cylinder head ……1021
Cylinder block ……1023
Crankshaft ……1025
Piston ……1026
Connecting rod ……1027
Timing gear ……1028
Camshaft ……1029
Valve system ……1030
Valve and valve guide ……1031
Rocker arm shaft, push rod, and tappet ……1032
Flywheel and flywheel housing ……1033
Lubrication system ……1035
Oil pump ……1035
Cooling system ……1037
Water pump ……1037
INDEX……1038
Komatsu 95E Series Diesel Engine Repair Service Manuals