PDF Shop Manual Komatsu 95E-7 SERIES Engine - 2 MB
Unlock comprehensive repair and maintenance information for the Komatsu 95E-7 Series Engine with this official shop manual.
This guide, publication number SEN06590-06, offers detailed specifications, disassembly, and assembly procedures.
It is the definitive resource for professional technicians looking to perform in-depth service.
Keep your Komatsu engine running reliably for years to come.
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SEN06590-06
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
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00 INDEX AND FOREWORD PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT
REMARK
The oil cleaning equipment can remove the ultra fine (approxi-
mately 3 μm) particles that the filter built in the hydraulic equip-
ment cannot remove. So, it is very effective device.
95LE-7 SERIES 00-29
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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
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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
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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 (D39EX-24, D39EXI-24, D39PX-24, D39PXI-24)
Engine model SAA4D95LE-7
No. of cylinders - bore x stroke mm 4-95 x 115
Piston displacement ℓ {cc} 3.260 {3260}
Firing order - 1-2-4-3
Overall length mm 1120
Overall width mm 697
Dimensions Overall height (excluding
mm -
exhaust pipe)
Overall height (including ex-
mm 1223
haust pipe)
kW {HP}/
Rated horsepower (Gross) 80 {107}/2200{2200}
min-1 {rpm}
Nm {kgfm}/
Max. torque (Gross) 415 {42.3}/1600{1600}
min-1 {rpm}
Performance Max. speed with no load
min-1 {rpm} 2370±50{2370±50}
(high idle speed)
Min. speed with no load
min-1 {rpm} 1075±25{1075±25}
(low idle speed)
Fuel consumption ratio at
g/kWh {g/HPh} 230 {172}
rated horsepower
Dry weight (aftertreatment devices are not inclu-
kg 653
ded)
Fuel injection system - High-pressure common rail type
Control of fuel injection system - Electronic control type
Quantity of lubricating oil (refill capacity) ℓ 12.5 (11.5)
Quantity of coolant ℓ (5.5 only engine)
Alternator - 24 V, 85 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
Rear view
1: Center of the crankshaft 2: Center of the cylinder
Dimension (D): 706 mm Dimension (G): 840 mm
Dimension (E): 339 mm Dimension (H): 323 mm
Dimension (F): 367 mm Dimension (J): 1163 mm
95LE-7 SERIES 01-25
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01 SPECIFICATIONS ENGINE PERFORMANCE CURVE
ENGINE PERFORMANCE CURVE: SAA4D95LE-7(PC138US-11, PC138USLC-11,
PC138US-11E0)
Rated output:72.6±3.6 kW {97.3±4.9 HP} /2050 min-1 {2050 rpm} (Gross)
Max. torque: 406±20 Nm {41.4±2.1 kgfm} /1530 min-1 {1530 rpm} (Gross)
600
400
Torque (Nm)
200
0
80
60
Flywheel horsepower (kW)
40
20
0
Engine speed (min-1)
$(
95LE-7 SERIES 01-35
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10 STRUCTURE AND FUNCTION 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 10-9
--- Page 15 ---
10 STRUCTURE AND FUNCTION FUNCTION OF UREA SCR SYSTEM
*3: These percentages show a torque reduction ratio from the full torque curve, and a speed reduction ratio from
the rated speed.
*4: Construction equipment with crawler
*5: Construction equipment with wheel
*6: After progressed “Severe Inducement” the status advances to “Final Inducement” with in 1 hour.
INDUCEMENT STRATEGY WHEN ABNORMALITY IS FOUND IN THE UREA SCR
SYSTEM DEVICES (FOR NORTH AMERICA)
• AdBlue/DEF system caution lamp lights up on machine monitor, and an action level is displayed when an
abnormality occurs in quality in AdBlue/DEF or in urea SCR system. In addition to the caution by the AdBl-
ue/DEF system caution lamp, alarm sounds as time passes after the abnormality occurred. Then, induce-
ment strategy starts so that the engine output is lowered.
• The Inducement strategy status and the categories of abnormalities can be checked on the “SCR Informa-
tion” screen of the machine monitor.
• The table shows warning indications and engine power derations by each Inducement strategy status.
Machine monitor
Elapsed Caution Failure code Engine de-
Status Message of lamp Failure code
time (*1) Tone of au- for Induce- ration (*5)
SCR Infor- for abnormali-
(Action lev- dible alert ment strategy
mation ty (*2),(*3)
el) status (*4)
Yellow
1: Please
inspect and CA3571
1 Warning 1 hour maintain No sound No indication No deration
SCR sys- Yellow CB3571
tem.
Yellow
2: Without Triplet (*6) AS00R2
Escalated treatment,
2 Warning 2 hours engine Short inter- CA3571 (Warning 2 No deration
power will Yellow mittently CB3571 (SCR Device
(Warning 2)
be derated. (*7) Abnormality))
Red
AS00R3
Mild In- 3: Engine
ducement power is Long inter- CA3571 (Inducement Torque: over
3 3 hours 1(SCR De-
(Induce- under dera- Red mittently CB3571 25%
tion. vice Abnor-
ment 1)
mality))
95LE-7 SERIES 10-19
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10 STRUCTURE AND FUNCTION FUNCTION OF UREA SCR SYSTEM
Display on machine monitor
Length of Failure code Failure code Engine de-
Status Message of Caution
time (*1) Alarm buz- for current for Induce- ration (*4)
SCR Infor- lamp
zer sound abnormality ment strategy
mation Action level (*2) status (*3)
Red
2: Without Yellow
AS00R2 Torque re-
Continuous treatment,
Warning Triple-beep (Warning 2 duction rate:
2 10 hours engine CA5391
alarm (*5) (SCR Device 25% or
(Warning 2) power will
be derated. Abnormality)) more
Red
Red
Red AS00R3
Low-Level 3: Engine Torque re-
Inducement power is Long inter- (Inducement duction rate:
3 20 hours CA5391 1 (SCR De-
(Induce- under dera- mittently 25% or
tion. vice Abnor- more
ment 1)
mality))
Red
Red
Torque re-
duction rate:
4: Engine Red AS00R4 50% or
Severe In-
Until abnor- power is (Inducement more
ducement Continuous
4 mality is re- under CA5391 2 (SCR De- Engine
(Induce- alarm
paired heavy dera- vice Abnor- speed re-
ment 2) tion. mality)) duction rate:
40% or
Red
more
*1: Length of time of each stage is accumulated time to go to the next stage after “Warning” stage is started.
95LE-7 SERIES 10-29
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10 STRUCTURE AND FUNCTION COMPONENT PARTS OF UREA SCR SYSTEM
AdBlue/DEF INJECTOR
STRUCTURE OF AdBlue/DEF INJECTOR
A: Pressurized sending from AdBlue/DEF pump
B: Coolant inlet
C: Coolant outlet
1: AdBlue/DEF injector
2: AdBlue/DEF inlet connector
3: Coolant inlet connector
4: Coolant outlet connector
5: Electric connector
FUNCTION OF AdBlue/DEF INJECTOR
• It injects AdBlue/DEF which is pressurized by AdBlue/DEF pump into AdBlue/DEF mixing tube.
• The injection amount is controlled by the valve opening or closing time while the pressure is constant.
• It circulates the engine coolant to prevent it from being heated by the heat from the exhaust pipe.
OPERATION OF AdBlue/DEF INJECTOR
Principle of injection of the injector is described. Following fig-
ure shows the state of injection.
1. Engine controller sends the electrical signal to control
AdBlue/DEF injector.
2. Solenoid (4) moves seal ball (2), and seal ball (2) leaves
from injection port (1) to make opening state.
Pressurized AdBlue/DEF by AdBlue/DEF pump is injected.
3. When the electrical signal is not sent, seal ball (2) closes
injection port (1) with spring force (3), so AdBlue/DEF is
not injected.
95LE-7 SERIES 10-39
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10 STRUCTURE AND FUNCTION INTAKE AND EXHAUST SYSTEM PARTS
AIR CLEANER
STRUCTURE OF AIR CLEANER
REMARK
The shape may vary depending on the machine models.
General view and sectional view
A: Intake air inlet B: Intake air outlet
1: Air flow and temperature sensor mounting portion 6: Inner element
2: Guide bane 7: Body
3: Vacuator valve 8: Inlet
4: Dust pan 9: Dust indicator mounting portion
5: Outer element 10: Outlet
SPECIFICATIONS OF AIR CLEANER
Type: CYCLOPAC
Filtering area (outer cylinder): 4.29 m2
Filtering area (inner cylinder): 0.096 m2
FUNCTION OF AIR CLEANER
Air cleaner is a device that separates dust by centrifugal separation effect of guide vane (2) when air with dust is
sucked into the air cleaner through inlet (8).
OPERATION OF AIR CLEANER
1. The intake air swirls along the guide vane and generates a centrifugal force since the inlet (8) is placed in
the tangential direction.
2. The dust in the intake air is separated by the centrifugal effect.
3. The inner element (6) removes dust 99.9 % or more, and cleaner air passes through outer element (5) and
is sucked into engine through outlet (10).
4. The dust and water which are removed during the air intake process swirl along the inside wall of body (7),
and is discharged out automatically through vacuator valve (3).
95LE-7 SERIES 10-49
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10 STRUCTURE AND FUNCTION ENGINE MAIN BODY PARTS
TIMING GEAR
STRUCTURE OF TIMING GEAR
REMARK
The shape may vary depending on the machine models.
Structural view
A, B, C: Gear matchmarks
1: Cam gear (number of teeth: 52) 5: Engine oil pump drive gear (number of teeth: 22)
2: Idler gear (number of teeth: 52) 6: Shaft
3: Supply pump drive gear (number of teeth: 26) 7: Bushing
4: Crank gear (number teeth: 26) 8: Thrust plate
95LE-7 SERIES 10-59
--- Page 20 ---
10 STRUCTURE AND FUNCTION TURBOCHARGER SYSTEM
• The open/close position of flow control valve (4) is controlled by driving the actuator according to the com-
mand from the engine controller.
95LE-7 SERIES 10-69
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10 STRUCTURE AND FUNCTION TURBOCHARGER SYSTEM
FORMING OF CONDENSED WATER AND EMULSION IN KCCV SYSTEM
A: Inside of KCCV piping C: Back of head cover
B: Inside of breather D: Level gauge
1: Air cleaner 5: Breather
2: Variable flow turbocharger 6: KCCV ventilator
3: Aftercooler 7: Engine oil pan
4: Engine
95LE-7 SERIES 10-79
--- Page 22 ---
10 STRUCTURE AND FUNCTION TURBOCHARGER SYSTEM
Structure
• The KDPF has a function to introduce the exhaust gas and consists of the inlet unit (1) that stores the oxi-
dation catalyst (KDOC), KCSF unit (4) that stores the soot collecting filter with the catalyst, and outlet unit
(5) that discharges the exhaust gas.
• The inlet unit (1) stores the KDOC which consists of the ceramic honeycomb with the oxidation catalyst.
• The ceramic honeycomb is used to optimize the 2 functions. The first is to oxidize NO (nitrogen monoxide)
contained in the exhaust gas into NO2 (nitrogen dioxide). The second is to burn the sprayed fuel during the
automatic regeneration or manual stationary regeneration. (Automatic regeneration is a method that purifies
(oxidize) the soot accumulated on the soot collecting filter (KCSF) in the KDPF.)
• The ceramic honeycomb is protected by a special fiber mat to prevent ceramic breakage caused by the en-
gine and body vibrations. It also prevents the high temperature around the KDPF caused by the high tem-
perature heat from the ceramics during operation.
• The KCSF unit (4) consists of the ceramic honeycomb with the oxidation catalyst same as the KDOC.
The ceramic honeycomb catches the soot.
The KCSF unit (4) consists of many cells divided by the ceramic walls inside. The cells blocked on the inlet
side and the cells blocked on the outlet side are put alternately.
• On the KDPF, the KDPF temperature sensor and the differential pressure sensor are installed. The KDPF
temperature sensor is an integrated unit that consists of the KDOC inlet temperature sensor, KDOC outlet
temperature sensor, and KDPF outlet temperature sensor. The differential pressure sensor is an integrated
unit that consists of the KDPF differential pressure sensor and KDPF outlet pressure sensor.
With the combination of the temperature values measured by the 3 temperature sensors, the KDPF temper-
ature sensor judges that the KCSF unit (4) and KDOC operate normally. It is also used for different types of
troubleshooting.
The differential pressure sensor senses the pressure difference between the two sides of the KCSF unit (4)
and monitors the soot accumulated in the KCSF unit (4). It is also used for different types of troubleshoot-
ing, similarly to the temperature sensor.
FUNCTION OF KDPF
A: Flow of exhaust gas
1: KDOC (oxidation catalyst)
2: KCSF
3: Seal (ceramic made)
4: Cell
5: Ceramics honeycomb
• The KDPF catches most of PM that is contained in the ex-
haust gas and purifies it. PM is particulate material such as
soot, or chains of the particulate soot.