Komatsu 95E -5 Series Engine Service Manual
449 pages · Publication SEN01966-16
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- Models
- 95E -5 Series
- Manual type
- Service Manual
- Pages
- 449
- Publication
- SEN01966-16
- Condition
- Brand new
What's inside
From the manual's own table of contents: 8 sections, 199 entries. See sample pages (PDF, 512 KB)
Index and foreword36 topics
- Shop Manual, contents binder, binder label and tabs
- Index and foreword
- Foreword and general information
- Specification
- Specification and technical data
- Structure, function and maintenance standard
- Structure, function and maintenance standard, Part 1
- Structure, function and maintenance standard, Part 2
- Standard value table
- Standard service value table
- Testing and adjusting
- Troubleshooting
- General information on troubleshooting
- Troubleshooting of electrical system (E-mode), Part 1
- Troubleshooting of electrical system (E-mode), Part 2
- Troubleshooting of mechanical system (S-mode)
- Disassembly and assembly
- General information on disassembly and assembly
- Disassembly and assembly, Part 1
- Disassembly and assembly, Part 2
- Disassembly and assembly, Part 3
- Repair and replacement of parts
- Information related to repair and replacement
- Parts related to cylinder head
- Parts related to cylinder block
- Composition of shop manual
- Safety notice
- How to read the shop manual
- Explanation of terms for maintenance standard
- Handling of electric equipment and hydraulic component
- Handling of connectors newly used for engines
- How to read electric wire code
- Precautions when carrying out operation
- Method of disassembling and connecting push-pull type coupler
- Standard tightening torque table
- Conversion table
Specification5 topics
- General information
- Specifications
- General view
- Weight table
- Engine performance curves
Structure, function and maintenance standard36 topics
- General structure
- Air intake and exhaust unit
- Air cleaner
- Turbocharger
- Muffler
- Cylinder head
- Cylinder block
- Cylinder
- Main moving parts
- Crankshaft
- Camshaft
- Piston, piston ring and piston pin
- Connecting rod
- Flywheel and flywheel housing
- Timing gear
- Valve system
- Valve, valve guide
- Rocker arm shaft, push rod and tappet
- Lubrication system diagram
- Oil pump
- Regulator valve
- Oil filter
- Fuel system diagram
- Supply pump
- Fuel injection nozzle
- Fuel filter
- Common rail
- Various sensor
- Cooling system diagram
- Water pump
- Cooling fan drive and thermostat
- Starting and charging system electrical circuit diagram
- Alternator
- Starting motor
- Starting aid
- Engine controller
Standard value table2 topics
- Standard service value table for testing, adjusting, and troubleshooting
- Running-in standard and performance test standard
Testing and adjusting18 topics
- Testing and adjusting tools list
- Sketches of special tools
- Measuring intake air pressure
- Testing exhaust temperature
- Adjusting valve clearance
- Testing compression pressure
- Testing blow-by pressure
- Testing oil pressure
- Handling fuel system parts
- Releasing residual pressure in fuel system
- Testing fuel pressure
- Reduced cylinder mode operation
- No-injection cranking
- Testing leakage from pressure limiter and return rate from injector
- Bleeding air from fuel circuit
- Testing fuel system for leakage
- Testing and adjusting alternator belt tension
- Handling controller voltage circuit
Troubleshooting65 topics
- Points on troubleshooting
- Error code and failure code table
- Information in troubleshooting table
- Connection table for connector pin numbers
- T- branch box and T- branch adapter table
- E-1 Code [111/CA111] ECM Critical Internal Failure
- E-2 Code [115/CA115] Eng. Ne and Bkup Speed Sensor Error
- E-3 Code [122/CA122] Charge Air Press Sensor High Error
- E-4 Code [123/CA123] Charge Air Press Sensor Low Error
- E-5 Code [131/CA131] Throttle Sensor High Error
- E-6 Code [132/CA132] Throttle Sensor Low Error
- E-7 Code [144/CA144] Coolant Temp. Sensor High Error
- E-8 Code [145/CA145] Coolant Temp. Sensor Low Error
- E-9 Code [153/CA153] Charge Air Temp. Sensor High Error
- E-10 Code [154/CA154] Charge Air Temp. Sensor Low Error
- E-12 Code [221/CA221] Ambient Air Press. Sensor High Error
- E-13 Code [222/CA222] Ambient Air Press. Sensor Low Error
- E-14 Code [227/CA227] Sensor Sup. 2 Volt. High Error
- E-16 Code [238/CA238] Ne Speed Sensor Sup. Volt. Error
- E-19 Code [322/CA322] Injector #1 System Open/Short Error
- E-20 Code [324/CA324] Injector #3 System Open/Short Error
- E-21 Code [331/CA331] Injector #2 System Open/Short Error
- E-22 Code [332/CA332] Injector #4 System Open/Short Error
- E-23 Code [351/CA351] INJ. Drive Circuit Error
- E-25 Code [386/CA386] Sensor Sup. 1 Volt. High Error
- E-26 Code [431/CA431] Idle Validation SW Low error
- E-27 Code [432/CA432] Idle Validation Process error
- E-28 Code [435/CA435] Abnormality in engine oil pressure switch
- E-29 Code [441/CA441] Battery voltage low error
- E-30 Code [442/CA442] Battery voltage high error
- E-31 Code [449/CA449] Rail Press. Very High Error
- E-32 Code [451/CA451] Rail Press. Sensor High Error
- E-33 Code [452/CA452] Rail Press. Sensor Low Error
- E-34 Code [553/CA553] Rail Press. High Error
- E-35 Code [559/CA559] Rail Press. Low Error
- E-36 Code [689/CA689] Eng. Ne Speed Sensor Error
- E-37 Code [731/CA731] Eng. Bkup Speed Sensor Phase Error
- E-38 Code [757/CA757] All Persistent Data Lost Error
- E-39 Code [778/CA778] Eng. Bkup Speed Sensor Error
- E-40 Code [1633/CA1633] KOMNET Dtalink Timeout Error
- E-41 Code [2185/CA2185] Throttle Sens. Sup. Volt. High Error
- E-42 Code [2186/CA2186] Throttle Sens. Sup. Volt. Low Error
- E-43 Code [2249/CA2249] Rail Press. Very Low Error
- E-44 Code [2311/CA2311] Abnormality in IMV solenoid
- E-45 Code [2555/CA2555] Grid Heater Relay Volt. Low Error
- E-46 Code [2556/CA2556] Grid Heater Relay Volt. High Error
- E-47 Code [(- - -)/B@BAZG] Eng. Oil press. Low Speed Derate
- E-48 Code [(- - -)/B@BAZG] Eng. Oil press. Torque Derate
- Method of using troubleshooting charts
- S-1 Starting performance is poor
- S-2 Engine does not start
- S-3 Engine does not pick up smoothly
- S-4 Engine stops during operations
- S-5 Engine does not rotate smoothly
- S-6 Engine lacks output (or lacks power)
- S-7 Exhaust smoke is black (incomplete combustion)
- S-8 Oil consumption is excessive (or exhaust smoke is blue)
- S-9 Oil becomes contaminated quickly
- S-10 Fuel consumption is excessive
- S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)
- S-12 Oil pressure drops
- S-13 Oil level rises (Entry of coolant or fuel)
- S-14 Coolant temperature becomes too high (overheating)
- S-15 Abnormal noise is made
- S-16 Vibration is excessive
Disassembly and assembly7 topics
- How to read this manual
- Coating materials list
- Special tools list
- General disassembly of engine
- General assembly of engine
- Disassembly and assembly procedure for fuel supply pump unit
- Disassembly and assembly procedure for oil seal units
Repair and replacement of parts22 topics
- Special tool table
- Part names related to cylinder head
- Testing and inspection of cylinder head
- Pressure test of cylinder head
- Replacement of valve guide
- Replacement of valve seat insert
- Repair of cylinder head mounting face by grinding
- Repair of valve by grinding
- Part names related to cylinder block
- Testing and inspection of cylinder block
- Part names related to crankshaft
- Testing and inspection of crankshaft
- Part names related to connecting rod
- Testing and inspection of connecting rod
- Replacement of flywheel ring gear
- Replacement of crankshaft gear
- Replacement of camshaft gear
- Replacement of connecting rod small end bushing
- Replacement of cam bushing
- Cylinder liner (Special part for repair)
- Rework drawing for counter bore
- Repair of crankshaft by grinding
Inside this manual
Real pages from this service manual (449 pages). Open the sample pages (PDF, 511 KB)
- Specifications, page 62: 01 Specification
- Diagram, page 272: Circuit diagram related to atmospheric pressure sensor
- Troubleshooting, page 308: E-34 Code [553/CA553] Rail Press. High Error
This is a service manual
Here's how it compares to the other manual types.
Service manual
Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.
Operator's manual
Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.
Parts manual
Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.
Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.
What it's used for
Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.
Service shops and owner/operators who repair their own equipment
Identifying correct parts and seeing how assemblies come apart and go back together
Keeping equipment running with less downtime
Factory manual, 449 pages
Quantity one is the manual described above.
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Binder not included
Manuals over about 300 pages may need a standard 3-ring binder, which you can buy locally to keep the pages organized for shop use.
Questions about model, serial number, engine coverage or contents? Contact us before purchasing and we'll help confirm it's the right manual. Please verify the manual type, machine model, serial number range and engine coverage before purchasing: manuals ordered in error carry a 20% restocking fee (return policy).