PDF Shop Manual Komatsu 95E-7 Series Engine - 2 MB
This is the complete shop manual for the Komatsu 95E-7 Series Engine.
It provides detailed, factory-approved procedures for engine overhaul, repair, and troubleshooting.
With clear diagrams and precise specifications, this manual is indispensable for any mechanic working on these engines.
Ensure your repairs are done correctly and efficiently with this comprehensive guide.
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SEN06590-05
ENGINE 95E -7 SERIES
--- Page 3 ---
00 INDEX AND FOREWORD ABBREVIATION LIST
Abbreviation Actual word spelled out
S/T
Steering
STRG
SIG Signal
SOL Solenoid
STD Standard
OPT
Option
OP
PRESS Pressure
SPEC Specification
SW Switch
TEMP Temperature
T/C Torque Converter
T/M Transmission
95LE-7 SERIES 00-9
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00 INDEX AND FOREWORD SAFETY NOTICE FOR OPERATION
REMARK
• The figure shows an example of fitting of O-ring.
• An O-ring is fitted to every joint of the air conditioner piping.
For tightening torques, see THE OTHER INFORMATION, “Pre-
cautions for disconnection and connection of air conditioner
piping”.
95LE-7 SERIES 00-19
--- Page 5 ---
00 INDEX AND FOREWORD PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT
REMARK
The oil cleaning equipment can remove the ultra fine (approxi-
mately 3 ÎĽm) particles that the filter built in the hydraulic equip-
ment cannot remove. So, it is very effective device.
95LE-7 SERIES 00-29
--- Page 6 ---
00 INDEX AND FOREWORD PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT
The machines equipped with common rail fuel injection system (CRI) consists of more precise parts than the
parts used in the conventional fuel injection pump and nozzle. If foreign material enters this system, it may
cause a failure. Use special care to prevent entry of the foreign material when servicing the fuel system.
Select an appropriate workplace
Avoid the work of adding hydraulic oil, replacing filters, or repairing the machine in rainy or windy weather, or in
dusty environment.
Sealing the opening
Plug the removed pipes and the openings of the removed components with the caps, tapes, plastic bags, etc. to
prevent foreign material from entering.
NOTICE
Do not expose the openings or stuff it, otherwise foreign
material may enter or leaked oil may pollute the environ-
ment.
Do not discard the oil inconsiderately. Ask the customer
for disposal or bring it back to dispose it appropriately.
How to clean parts when dirt is stuck
If any dirt or dust sticks the parts of the fuel system, clean it off thoroughly with clean fuel.
Precautions for replacing fuel filter cartridge
Be sure to use the Komatsu genuine fuel filter cartridge.
NOTICE
The machine equipped with common rail fuel injection system (CRI) consists of more precise parts than
the parts used in the conventional fuel injection pump and nozzle. In order to prevent foreign material
from entering this system, the filter employs a specially high performance of filter element. If a filter oth-
er than a Komatsu genuine filter is used, fuel system contamination and damage may occur. Therefore
Komatsu recommends using only Komatsu fuel filters and install them following the procedures in the
shop manual.
95LE-7 SERIES 00-39
--- Page 7 ---
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH
00 INDEX AND FOREWORD CONNECTOR
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNEC-
TOR
Method for disconnecting Deutsch connector
While pressing locks (a) and (b) from each side respectively,
pull out female connector (2).
Method for connecting Deutsch connector
1. Push in female connector (2) horizontally, and insert it
straight until it clicks. (Arrow: x)
2. In order to check whether locks (a) and (b) are completely
inserted, insert female connector (2) by rocking it vertically
(in the arrow z direction). (Arrow: x, y, z)
REMARK
Lock (a) in the figure is pulled down (not set completely),
and lock (b) is set completely.
95LE-7 SERIES 00-49
--- Page 8 ---
00 INDEX AND FOREWORD HOW TO READ ELECTRICAL WIRE CODE
Types of circuits and color codes
Type of wire AVS, AV, CAVS AEX
Charge R WG - - - - R -
Ground B - - - - - B -
Start R - - - - - R -
Light RW RB RY RG RL - O -
Instrument Y YR YB YG YL YW Y Gr
Signal G GW GR GY GB GL G Br
L LW LR LY LB - L -
Type of circuit Br BrW BrR BrY BrB - - -
Lg LgR LgY LgB LgW - - -
O - - - - - - -
Others Gr - - - - - - -
P - - - - - - -
Sb - - - - - - -
Dg - - - - - - -
Ch - - - - - - -
95LE-7 SERIES 00-59
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00 INDEX AND FOREWORD STANDARD TIGHTENING TORQUE TABLE
Thread diameter (mm) Tightening torque (Nm {kgfm} )
6 8±2 {0.81±0.20}
8 10±2 {1.02±0.20}
10 12±2 {1.22±0.20}
12 24±4 {2.45±0.41}
14 36±5 {3.67±0.51}
Tightening torque table for tapered screws on 102, 107, and 114 series engines
(National taper pipe thread (NPT))
REMARK
Tighten the National taper pipe threaded (NPT) screws used on the 102, 107, and 114 series engines to the
torques shown in the following table unless otherwise specified.
Material of female screw In cast iron or steel In aluminum
Nominal thread size Tightening torque (Nm {kgfm} ) Tightening torque (Nm {kgfm} )
1/ 15±2 {1.53±0.20} 5±1 {0.51±0.10}
16
1/ 20±2 {2.04±0.20} 15±2 {1.53±0.20}
8
1/ 25±3 {2.55±0.31} 20±2 {2.04±0.20}
4
3/ 35±4 {3.57±0.41} 25±3 {2.55±0.31}
8
1/ 55±6 {5.61±0.61} 35±4 {3.57±0.41}
2
3/ 75±8 {7.65±0.82} 45±5 {4.59±0.51}
4
95LE-7 SERIES 00-69
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01 SPECIFICATIONS ABBREVIATION LIST
Purpose of use (major ap-
Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
A general term for the engineering and its social-
Information and Com- Communication and elec-
ICT ly applied technology of information processing
munication Technology tronic control
and communication.
This is a valve that adjusts the fuel intake amount
IMA Inlet Metering Actuator Engine at the pump inlet in order to control the supply
pump fuel discharged volume. (Same as IMV)
This is a device to detect the angle (or angular
Inertial Measurement
IMU Engine velocity) and acceleration of the 3 axes that con-
Unit
trol motions.
This is a valve that adjusts the fuel intake amount
at the pump inlet in order to control the supply
IMV Inlet Metering Valve Engine
pump combustion discharged volume. (Same as
IMA)
This is a mechanism that burns the blowby gas
Komatsu Closed Crank- again by separating oil from blowby gas and re-
KCCV Engine
case Ventilation turning it to the intake side. It primarily consists of
filters.
Komatsu Catalyzed This is a filter that captures soot in exhaust gas.
KCSF Engine
Soot Filter It is built in to KDPF.
This is a catalyst that is used for purifying ex-
Komatsu Diesel Oxida- haust gas.
KDOC Engine
tion Catalyst It is built in to KDPF or assembled with the muf-
fler.
This is a component that is used to purify the ex-
Komatsu Diesel Particu- haust gas. KDOC (catalyst) and KCSF (filter to
KDPF Engine capture soot) are built-in it.
late Filter
It is installed instead of the conventional muffler.
Travel and brake This is a function that performs braking with the
optimum force and recovers the driving force of
Komatsu Traction Con-
KTCS the wheels by actuating the inter-axle differential
trol System (HM) lock when the wheels runs idle while the machine
travels on the soft ground.
This is an image display equipment such as a
LCD Liquid Crystal Display Machine monitor monitor in which the liquid crystal elements are
assembled.
This is a semiconductor element that emits light
LED Light Emitting Diode Electronic parts
when the voltage is applied in forward direction.
Local Interconnect Net- Communication and elec- This is one of communication standards that are
LIN
work tronic control used in the network on the machine.
This is a function that detects differential pres-
LS Load Sensing Hydraulic system sure of pump, and controls discharged volume
corresponding to load.
Low Voltage Differential Communication and elec- This is one of communication standards that are
LVDS
Signaling tronic control used in the network on the machine.
This indicates engine intake air flow. This is not
used independently but is used as combined with
MAF Mass Air Flow Engine
sensor. Mass air flow sensor can be called as
MAF sensor.
95LE-7 SERIES 01-5
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01 SPECIFICATIONS SPECIFICATIONS
SPECIFICATIONS: SAA4D95LE-7 (PC130-11)
Engine model SAA4D95LE-7
No. of cylinders - bore x stroke mm 4-95 x 115
Piston displacement â„“ {cc} 3.260 {3260}
Firing order - 1-2-4-3
Overall length mm 761
Overall width mm 706
Dimensions Overall height (excluding
mm 1163
exhaust pipe)
Overall height (including ex-
mm -
haust pipe)
kW {HP}/
Rated horsepower (Gross) 72.6 {97.3}/2050{2050}
min-1 {rpm}
Nm {kgfm}/
Max. torque (Gross) 406 {41.3}/1530{1530}
min-1 {rpm}
Performance Max. speed with no load
min-1 {rpm} 2150±60{2150±60}
(high idle speed)
Min. speed with no load
min-1 {rpm} 1100±50{1100±50}
(low idle speed)
Fuel consumption ratio at
g/kWh {g/HPh} 226 {169}
rated horsepower
Dry weight (aftertreatment devices are not inclu-
kg 430
ded)
Fuel injection system - High-pressure common rail type
Control of fuel injection system - Electronic control type
Quantity of lubricating oil (refill capacity) â„“ 12.5 (11.5)
Quantity of coolant â„“ (5.5 only engine)
Alternator - 24 V, 60 A
Starting motor - 24 V, 4.5 kW
Variable flow turbocharger - TD04M4t-09KYRCN-SVFT
95LE-7 SERIES 01-15
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01 SPECIFICATIONS ENGINE GENERAL VIEW
ENGINE GENERAL VIEW: SAA4D95LE-7 (PC138US-11, PC138USLC-11)
REMARK
The shape may vary depending on the machine models.
Left side view
1: Center of the crankshaft 2: Rear face of the flywheel housing
Dimension (A): 924 mm Dimension (C): 163 mm
Dimension (B): 761 mm
95LE-7 SERIES 01-25
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10 STRUCTURE AND FUNCTION
95LE-7 SERIES 10-1
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10 STRUCTURE AND FUNCTION LAYOUT DRAWING OF UREA SCR SYSTEM
12: Ambient temperature sensor 15: AdBlue/DEF return hose
13: AdBlue/DEF tank sensor 16: AdBlue/DEF suction hose
14: AdBlue/DEF filler port
17: SCR outlet temperature sensor 21: SCR outlet NOx sensor
18: Engine room temperature sensor 22: Ammonia sensor
19: KDOC inlet temperature sensor 23: Turbocharger outlet NOx sensor
20: KDOC outlet temperature sensor 24: SCR temperature sensor
95LE-7 SERIES 10-11
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10 STRUCTURE AND FUNCTION FUNCTION OF UREA SCR SYSTEM
heavily. This may cause difficulties of moving the machine to a safe place for adding AdBlue/DEF or trou-
bleshooting and correcting abnormalities of the Urea SCR system. For temporary remedies from these diffi-
culties the operator can restore engine power for a short time to the deration of “Mild Inducement” through
the machine monitor. Note that “Temporary Restoration from Inducement” does not regain full engine pow-
er.
• “Temporary Restoration from Inducement” can be activated only when the Urea SCR system is in “Severe
Inducement”. The maximum duration is limited to 30 minutes in each restoration operation, and 3 opera-
tions are allowed, but “Temporary Restoration from Inducement” is turned off whenever the system advan-
ces to “Final Inducement” even if either 30 minutes or 3 operations are not used up. All the abnormalities of
the Urea SCR system need to be corrected to regain another restoration capability.
• If all the abnormalities of the Urea SCR system are not corrected when the system is in “Severe Induce-
ment”, the system advances to “Final Inducement” in 1 hour after “Severe Inducement” started and engine
speed will be fixed to low idle to disable practical machine operation.
• To activate Temporary Restoration, follow the procedures described below.
REMARK
For the operating procedure on this function, refer to “TEMPORARY RESTORATION FROM INDUCE-
MENT” on the OPERATION section in the Operation and Maintenance Manual.
INDUCEMENT STRATEGY FOR ABNORMALITY RECURRENCE WITHIN 40
HOURS (FOR NORTH AMERICA)
• The Urea SCR system continuously monitors its operation conditions and stores information on inappropri-
ate operations including malfunctions.
• The stored information is utilized to monitor recurrences of abnormalities, “Abnormality Counter”. “Abnor-
mality Counter” is required by the authorities. The abnormality counting spans 40 hours and it monitors the
abnormalities that trigger Inducement other than the amount of AdBlue/DEF in the tank.
• If another abnormality/abnormalities is detected within 40 hours after the previous abnormalities were cor-
rected, regardless of the level of the previous Inducement and whether the new abnormality/abnormalities
is the same as the previous ones or not, it is judged as a recurrence.
• If a recurrence occurs, the Inducement strategy will be activated and starts from “Severe Inducement”.
• The duration of “Severe Inducement” in the recurrence is limited to 30 minutes. If the abnormalities are not
corrected while Inducement is in “Severe Inducement (30 minutes)”, Inducement will advance to “Final In-
ducement” and engine speed will be fixed to low idle to disable practical machine operation.
INDUCEMENT STRATEGY WHEN THE AdBlue/DEF LEVEL IN THE TANK BE-
COMES LOW (FOR EUROPEAN UNION)
• When the AdBlue/DEF level in the tank becomes low, AdBlue/DEF level caution lamp on the machine moni-
tor lights up, the Audible alert sounds, the action level is displayed and Inducement strategy including en-
gine power deration is activated.
• The Inducement strategy progresses in 4 levels from Warning, Continuous Warning, Low-Level Induce-
ment, and Severe Inducement.
• Up to the start of Severe Inducement the start of each warning step is triggered by the amount of
AdBlue/DEF in the AdBlue/DEF tank.
• The Inducement strategy status can be checked on “SCR Information” screen of the user menu.
• The table shows warning indications and engine power derations by each Inducement strategy status.
95LE-7 SERIES 10-21
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10 STRUCTURE AND FUNCTION COMPONENT PARTS OF UREA SCR SYSTEM
9: Catalyzer hold mat 12: Downstream SCR catalyst and ammonia oxidation
10: Rectifier tube catalyst (integrated type)
11: Upstream SCR catalyst 13: Water dam
• SCR assembly consists of rectifier tube (10) equalizing the distribution of flow speed by leading exhaust
gas, upstream SCR catalyst (11), downstream SCR catalyst, ammonia oxidation catalyst (integrated type)
(12), and water dam (13) which prevents rain water from entering into downstream SCR catalyst and am-
monia oxidation catalyst (integrated type) (12) while exhausting gas.
• Ammonia oxidation catalyst (a part of 12) oxidizes ammonia to water and nitrogen with ammonia oxidation
catalyst (a part of 12) to prevent ammonia which is supplied to SCR assembly from being released out be-
cause SCR catalyst (a part of 12, 11) cannot completely consume it.
• Each 1 piece of SCR temperature sensor (2), SCR outlet temperature sensor (5), ammonia sensor (3), and
SCR outlet NOx sensor (4) are installed. These sensors are usable for various troubleshooting, such as
they are used to control the feedback of denitration efficiency or they monitor that SCR catalyst properly
functions or not.
• Rectifying tube (10) equalizes the distribution of exhaust gas flow speed.
• SCR catalyst (a part of 12, 11) uses the ceramic honeycomb.
• The catalyzer holding mat (9) is made of a specific fiber and protects the ceramic catalyst against vibrations
by the engine and the machine body. It also protects the outer periphery of SCR assembly against a heat
transfer of the ceramics during operation.
• Water dam (13) is located at the upstream side of the outlet and prevents rainwater from entering into
downstream SCR catalyst unit and ammonia oxidation catalyst (integrated type) (12).
• Water baffle (6) is located at the downstream side of the outlet and prevents rainwater at outlet from splash-
ing over the detection part of NOx sensor.
95LE-7 SERIES 10-31
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10 STRUCTURE AND FUNCTION LAYOUT OF ENGINE COMPONENTS
44: Fuel filter 46: Common rail
45: Intake manifold 47: Supply pump
95LE-7 SERIES 10-41
--- Page 18 ---
10 STRUCTURE AND FUNCTION ENGINE MAIN BODY PARTS
Sectional view
7: Engine oil pump drive shaft bushing 8: Engine oil pump driven shaft
SPECIFICATIONS OF CYLINDER BLOCK
Cylinder block
Crankshaft: 5 bearings
Camshaft part: 3 bearings
Cylinder
Liner-less
Machining of inside surface: Honing
95LE-7 SERIES 10-51
--- Page 19 ---
10 STRUCTURE AND FUNCTION ENGINE MAIN BODY PARTS
FLYWHEEL AND FLYWHEEL HOUSING
STRUCTURE OF FLYWHEEL AND FLYWHEEL HOUSING
REMARK
The shape may vary depending on the machine models.
General view and sectional view
1: Starting motor 4: Rear seal
2: Flywheel housing 5: Flywheel
3: Crankshaft 6: Ring gear
95LE-7 SERIES 10-61
--- Page 20 ---
10 STRUCTURE AND FUNCTION TURBOCHARGER SYSTEM
EGR COOLER
EGR
Abbreviation for Exhaust Gas Recirculation
STRUCTURE OF EGR COOLER
REMARK
The shape is subject to machine models.
General view and sectional view
A: EGR gas inlet D: EGR gas outlet
B: Air vent E: Coolant inlet
C: Coolant outlet
1: Tube 2: Shell
1: Flat tube 2: Inner fin
95LE-7 SERIES 10-71
--- Page 21 ---
10 STRUCTURE AND FUNCTION TURBOCHARGER SYSTEM
KDOC
KDOC
Abbreviation for Komatsu Diesel Oxidation Catalyst
STRUCTURE OF KDOC
REMARK
The shape may vary depending on the machine models.
General view
A: From exhaust throttle valve B: To AdBlue/DEF mixing pipe
1: KDOC 4: KDOC outlet temperature sensor insertion opening
2: Exhaust gas outlet pipe 5: KDOC inlet temperature sensor insertion opening
3: Exhaust gas inlet pipe
Structure
• KDOC consists of the inlet pipe (3) which leads the exhaust gas from the engine, the KDOC (1) which
stores the oxidation catalyst, and the outlet pipe (2) which discharges the exhaust gas. All of these parts
are welded as a unit.
• KDOC (1) consists of ceramic honeycomb equipped with the oxidation catalyst.
• The ceramic honeycomb is protected with a mat made of special fibers to prevent breakage of the ceramics
under the vibration condition of the engine and machine body.
• KDOC inlet temperature sensor and KDOC outlet temperature sensor are installed to the KDOC.
The two temperature sensors that KDOC oxidation catalyst is functioning normally, and uses those temper-
atures for troubleshooting of various components.
95LE-7 SERIES 10-81
--- Page 23 ---
10 STRUCTURE AND FUNCTION LUBRICATION SYSTEM
ENGINE OIL PAN
STRUCTURE OF ENGINE OIL PAN
REMARK
The shape may vary depending on the machine models.
1: Engine oil drain plug 3: Engine oil suction pipe (with strainer)
2: Engine oil pan
95LE-7 SERIES 10-91
--- Page 24 ---
10 STRUCTURE AND FUNCTION COOLING SYSTEM
COOLING SYSTEM
LAYOUT DRAWING OF COOLING SYSTEM PARTS
REMARK
The shape may vary depending on the machine models.
A: From radiator B: To radiator
1: Water pump 3: Engine oil cooler
2: EGR cooler
95LE-7 SERIES 10-101
--- Page 25 ---
10 STRUCTURE AND FUNCTION COMPONENT PARTS OF ELECTRICAL SYSTEM
Specifications: 24 V, 60 A
Number of pulley grooves: 8
Outside diameter of pulley: 77.5 mm
Weight: 6.3 kg
STRUCTURE OF ALTERNATOR WITH BUILT-IN REGULATOR (OPEN TYPE, 85A)
REMARK
The shape may vary depending on the machine models.
General view and circuit diagram
1: Alternator (body) 6: Internal wiring diagram
2: Alternator pulley 6A: Field coil
3: Terminal R 6B: Initial excitation resistance
4: Terminal B 6C: Regulator
5: Terminal E
SPECIFICATIONS OF ALTERNATOR WITH BUILT-IN REGULATOR (OPEN TYPE,
85A)
Type: Manufactured by NIKKO DENKI, open type
Specifications: 24 V, 85 A
95LE-7 SERIES 10-111
--- Page 26 ---
10 STRUCTURE AND FUNCTION COMPONENT PARTS OF ELECTRICAL SYSTEM
Input and output
Pin No. Signal name
signals
Ground/Shield/
74 Injector #3 (-)
Return
Ground/Shield/
75 Injector #2 (-)
Return
76 (*1) -
77 (*1) -
78 Sensor 5 V power supply Power supply
79 Sensor 5 V power supply Power supply
80 Sensor 12 V power supply Power supply
81 Sensor 5 V power supply Power supply
82 Sensor 5 V power supply Power supply
83 Coolant temperature sensor Input
84 (*1) -
85 (*1) -
86 (*1) -
87 Common rail pressure sensor Input
88 (*1) -
89 (*1) -
90 (*1) -
91 (*1) -
92 (*1) -
93 Datalink 2 (-) (VFT controller) Communication
94 Datalink 3 (-) (KOMNET/r) Communication
95 (*1) -
96 (*1) -
*1: Never connect these pins. Malfunctions or failures may occur.
Delphi96Pin“CN-CE02/CN-J2”
Input and output
Pin No. Signal name
signals
1 Power supply (+24 V continuous) Power supply
2 (*1) -
3 AdBlue/DEF line heater relay 1 Output
4 (*1) -
5 ACC (Key SW) Input
6 AdBlue/DEF pump temperature sensor/ AdBlue/DEF pump driver Input and output
7 AdBlue/DEF line heater relay 2 Output
8 Sensor 5 V power supply Power supply
9 Sensor 5 V power supply Power supply
10 Throttle sensor Input
95LE-7 SERIES 10-121
--- Page 27 ---
10 STRUCTURE AND FUNCTION SENSOR
STRUCTURE OF NE (CRANKSHAFT) SPEED SENSOR
Attached to the crankshaft pulley part of engine front cover.
General view
1: O-ring (FRAMATOME-3P) 3: Connector
2: Sensor
FUNCTION OF NE (CRANKSHAFT) SPEED SENSOR
It outputs pulse voltage by the rotation of the gear.
STRUCTURE OF Bkup (CAMSHAFT) SPEED SENSOR
Attached to the camshaft gear portion of engine front cover.
General view