Shop Manual 95e-5 Series

SEN01966-00
ENGINE 95E -5 SERIES

SEN02121-00
ENGINE 1SHOP MANUAL
95E-5 Series
00 Index and foreword 1

Index
Composition of shop manual................................................................................................................ 2

Table of contents .................................................................................................................................. 3
95E-5 Series 1
SEN02121-00 00 Index and foreword
Composition of shop manual 1

The contents of this shop manual are shown together with Form No. in a list.
Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly.
The marks shown to the right of Form No. denote the following:
Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.)
Note 2: This shop manual can be supplied for each Form No.
Note 3: To file this shop manual in the special binder for management, handle it as follows:
Place a divider on the top of each section in the file after matching the Tub No. with No. indicated
next to each Section Name shown in the table below:
File overview and other materials in sections in the order shown below and utilize them accord-
ingly.
Section Title Form Number
Shop Manual, contents binder, binder label and tabs SEN01966-00
00 Index and foreword SEN02120-00

Index SEN02121-00
Foreword and general information SEN02122-00
01 Specification SEN02123-00
Specification and technical data SEN02124-00
10 Structure, function and maintenance standard SEN02125-00

Structure, function and maintenance standard, Part 1 SEN02126-00
20 Standard value table SEN02128-00

Standard service value table SEN02129-00
30 Testing and adjusting SEN02130-00

Testing and adjusting SEN02182-00
40 Troubleshooting SEN02131-00
General information on troubleshooting SEN02183-00
Troubleshooting of electrical system (E-mode), Part 1 SEN02185-00
Troubleshooting of mechanical system (S-mode) SEN02184-00
2 95E-5 Series
Table of contents 1
00 Index and foreword
Index SEN02121-00
Composition of shop manual....................................................................................................... 2
Table of contents ......................................................................................................................... 3
Foreword and general information SEN02122-00

Safety notice ............................................................................................................................... 2
How to read the shop manual ..................................................................................................... 7
Explanation of terms for maintenance standard.......................................................................... 9
Handling electric equipment and hydraulic component............................................................... 11
How to read electric wire code .................................................................................................... 23
Precautions when carrying out operation.................................................................................... 26
Method of disassembling and connecting push-pull type coupler............................................... 29
Standard tightening torque table ................................................................................................. 32
Conversion table ......................................................................................................................... 36
01 Specification
Specification and technical data SEN02124-00
Outline......................................................................................................................................... 2
Specifications .............................................................................................................................. 4
General view ............................................................................................................................... 5
Weight table ................................................................................................................................ 8
Engine performance curves ........................................................................................................ 9
10 Structure, function and maintenance standard

General structure ........................................................................................................................ 4
Air intake and exhaust system .................................................................................................... 6
Air intake and exhaust unit ...................................................................................................... 6
Air cleaner ............................................................................................................................... 8
Turbocharger ........................................................................................................................... 10
Muffler...................................................................................................................................... 13
Engine unit .................................................................................................................................. 14
Cylinder head .......................................................................................................................... 14
Cylinder block .......................................................................................................................... 16
Cylinder ................................................................................................................................... 19
Main moving parts ................................................................................................................... 20
Crankshaft ............................................................................................................................... 22
Camshaft ................................................................................................................................. 23
Piston, piston ring and piston pin............................................................................................. 24
Connecting rod ........................................................................................................................ 25
Flywheel and flywheel housing................................................................................................ 26
Timing gear.............................................................................................................................. 28
Valve system ........................................................................................................................... 32
Valve, valve guide.................................................................................................................... 34
Rocker arm shaft, push rod and tappet ................................................................................... 35
Lubrication system ...................................................................................................................... 3
Lubrication system diagram..................................................................................................... 3
Oil pump .................................................................................................................................. 4
Regulator valve........................................................................................................................ 6
Oil filter .................................................................................................................................... 7
Fuel system................................................................................................................................. 9
Fuel system diagram ............................................................................................................... 9
Supply pump............................................................................................................................ 10
95E-5 Series 3
Fuel injection nozzle ................................................................................................................ 12

Fuel filter .................................................................................................................................. 13
Common rail ............................................................................................................................ 14
Various sensor ......................................................................................................................... 16
Cooling system............................................................................................................................ 18
Cooling system diagram .......................................................................................................... 18
Water pump ............................................................................................................................. 19
Cooling fan drive and thermostat............................................................................................. 22
Electrical equipment .................................................................................................................... 26
Starting and charging system electrical circuit diagram........................................................... 26
Alternator ................................................................................................................................. 27
Starting motor .......................................................................................................................... 29
Starting aid............................................................................................................................... 30
Engine controller...................................................................................................................... 31
20 Standard value table

Standard service value table SEN02129-00
Standard service value table for testing, adjusting, and troubleshooting .................................... 2
Running-in standard and performance test standard .................................................................. 3
30 Testing and adjusting

Testing and adjusting SEN02182-00
Testing and adjusting tools list..................................................................................................... 3
Measuring intake air pressure ..................................................................................................... 4
Testing exhaust temperature ....................................................................................................... 5
Adjusting valve clearance............................................................................................................ 6
Testing compression pressure..................................................................................................... 8
Testing blow-by pressure............................................................................................................. 10
Testing oil pressure ..................................................................................................................... 11
Handling fuel system parts .......................................................................................................... 12
Releasing residual pressure in fuel system................................................................................. 12
Testing fuel pressure ................................................................................................................... 13
Reduced cylinder mode operation............................................................................................... 14
No-injection cranking................................................................................................................... 14
Testing leakage from pressure limiter and return rate from injector ............................................ 15
Bleeding air from fuel circuit ........................................................................................................ 18
Testing fuel system for leakage ................................................................................................... 20
Testing and adjusting alternator belt tension ............................................................................... 21
Handling controller voltage circuit ............................................................................................... 22
40 Troubleshooting
General information on troubleshooting SEN02183-00
Points on troubleshooting............................................................................................................ 2
Error code and failure code table ................................................................................................ 4
Information in troubleshooting table ............................................................................................ 6
E-1 Code [111/CA111] ECM Critical Internal Failure ................................................................... 4
E-2 Code [115/CA115] Eng. Ne and Bkup Speed Sensor Error .................................................. 7
E-3 Code [122/CA122] Charge Air Press Sensor High Error ...................................................... 8
E-4 Code [123/CA123] Charge Air Press Sensor Low Error....................................................... 10
E-5 Code [131/CA131] Throttle Sensor High Error ..................................................................... 11
E-6 Code [132/CA132] Throttle Sensor Low Error ...................................................................... 14
E-7 Code [144/CA144] Coolant Temp. Sensor High Error .......................................................... 15
E-8 Code [145/CA145] Coolant Temp. Sensor Low Error ........................................................... 16
E-9 Code [153/CA153] Charge Air Temp. Sensor High Error ..................................................... 18
E-10 Code [154/CA154] Charge Air Temp. Sensor Low Error .................................................... 20
E-11 Code [187/CA187] Sensor Sup. 2 Volt. Low Error .............................................................. 21
4 95E-5 Series
E-12 Code [221/CA221] Ambient Air Press. Sensor High Error ................................................. 22
E-13 Code [222/CA222] Ambient Air Press. Sensor Low Error .................................................. 24
E-14 Code [227/CA227] Sensor Sup. 2 Volt. High Error............................................................. 25
E-15 Code [234/CA234] Eng. Overspeed ................................................................................... 27
E-16 Code [238/CA238] Ne Speed Sensor Sup. Volt. Error ....................................................... 28
E-17 Code [271/CA271] IMV Short Error .................................................................................... 30
E-18 Code [272/CA272] IMV Open Error.................................................................................... 32
E-19 Code [322/CA322] Injector #1 (L/B #1) System Open/Short Error ..................................... 34
E-23 Code [351/CA351] INJ. Drive Circuit Error ......................................................................... 42
E-24 Code [352/CA352] Sensor Sup. 1 Volt. Low Error.............................................................. 45
E-25 Code [386/CA386] Sensor Sup. 1 Volt. High Error............................................................. 46
E-26 Code [431/CA431] Idle Validation SW Low error................................................................ 48
E-27 Code [432/CA432] Idle Validation Process error ................................................................ 48
E-28 Code [435/CA435] Abnormality in engine oil pressure switch............................................ 49
E-29 Code [441/CA441] Battery voltage low error ...................................................................... 50
E-30 Code [442/CA442] Battery voltage high error..................................................................... 50
E-31 Code [449/CA449] Rail Press. Very High Error .................................................................. 3
E-32 Code [451/CA451] Rail Press. Sensor High Error .............................................................. 4
E-33 Code [452/CA452] Rail Press. Sensor Low Error............................................................... 6
E-34 Code [553/CA553] Rail Press. High Error .......................................................................... 7
E-35 Code [559/CA559] Rail Press. Low Error ........................................................................... 8
E-36 Code [689/CA689] Eng. Ne Speed Sensor Error ............................................................... 12
E-37 Code [731/CA731] Eng. Bkup Speed Sensor Phase Error................................................. 14
E-38 Code [757/CA757] All Persistent Data Lost Error............................................................... 15
E-39 Code [778/CA778] Eng. Bkup Speed Sensor Error............................................................ 16
E-40 Code [1633/CA1633] KOMNET Dtalink Timeout Error....................................................... 18
E-41 Code [2185/CA2185] Throttle Sens. Sup. Volt. High Error................................................. 19
E-42 Code [2186/CA2186] Throttle Sens. Sup. Volt. Low Error.................................................. 22
E-43 Code [2249/CA2249] Rail Press. Very Low Error............................................................... 23
E-44 Code [2311/CA2311] Abnormality in IMV solenoid ............................................................. 24
E-45 Code [2555/CA2555] Grid Heater Relay Volt. Low Error.................................................... 26
E-46 Code [2556/CA2556] Grid Heater Relay Volt. High Error................................................... 28
E-48 Code [(---)/B@BAZG] Eng. Oil press. Torque Derate ........................................................ 30
E-47 Code [(---)/B@BAZG] Eng. Oil press. Low Speed Derate ................................................. 30
E-49 Code [(---)/B@BCNS] Eng. Overheat ................................................................................ 31
Troubleshooting of mechanical system (S-mode) SEN02184-00
Method of using troubleshooting charts ...................................................................................... 4
S-1 Starting performance is poor ................................................................................................ 8
S-2 Engine does not start............................................................................................................ 9
S-3 Engine does not pick up smoothly........................................................................................ 12
S-4 Engine stops during operations ............................................................................................ 13
S-5 Engine does not rotate smoothly .......................................................................................... 14
S-6 Engine lacks output (or lacks power).................................................................................... 15
S-7 Exhaust smoke is black (incomplete combustion)................................................................ 16
S-8 Oil consumption is excessive (or exhaust smoke is blue) .................................................... 17
S-9 Oil becomes contaminated quickly ....................................................................................... 18
S-10 Fuel consumption is excessive........................................................................................... 19
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) ................................. 20
S-12 Oil pressure drops .............................................................................................................. 21
S-13 Oil level rises (Entry of coolant or fuel)............................................................................... 22
S-14 Coolant temperature becomes too high (overheating) ....................................................... 23
S-15 Abnormal noise is made ..................................................................................................... 24
S-16 Vibration is excessive ......................................................................................................... 25
95E-5 Series 5
SEN02121-00
KOMATSU 95E-5 Series engine
Form No. SEN02121-00
2006 KOMATSU
All Rights Reserved
Printed in Japan 12-06 (01)
6
SEN02122-00
ENGINE 1SHOP MANUAL
95E-5 Series
00 Index and foreword 1

Foreword and general information
Safety notice ................................................................................................................................................... 2
How to read the shop manual ......................................................................................................................... 7
Explanation of terms for maintenance standard ............................................................................................. 9
Handling electric equipment and hydraulic component .................................................................................11
How to read electric wire code...................................................................................................................... 23
Precautions when carrying out operation...................................................................................................... 26
Method of disassembling and connecting push-pull type coupler................................................................. 29
Standard tightening torque table ................................................................................................................... 32
Conversion table ........................................................................................................................................... 36
95E-5 Series 1
Safety notice 1 (Rev. 2006/09)

Important safety notice
Proper service and repair are extremely important for safe machine operation. The service and repair
techniques recommended by Komatsu and described in this manual are both effective and safe.
Some of these techniques require the use of tools specially designed by Komatsu for the specific
purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The
cautions accompanying these symbols should always be followed carefully. If any dangerous situa-
tion arises or may possibly arise, first consider safety, and take the necessary actions to deal with
the situation.
1. General precautions 7) If welding repairs are needed, always

k Mistakes in operation are extremely have a trained and experienced welder
dangerous. Read the Operation and carry out the work. When carrying out
Maintenance Manual carefully before w elding work, alw ays wear welding
operating the machine. gloves, apron, shielding goggles, cap and
1) Before carrying out any greasing or other clothes suited for welding work.
repairs, read all the safety plates stuck to 8) Before starting work, warm up your body
the machine. For the locations of the thoroughly to start work under good condi-
safety plates and detailed explanation of tion.
precautions, see the Operation and Main-
tenance Manual. Safety points
2) Decide a place in the repair workshop to
keep tools and removed parts. Always 1 Good arrangement
keep the tools and parts in their correct 2 Correct work clothes
places. Always keep the work area clean 3 Following work standard
and make sure that there is no dirt, water,
or oil on the floor. Smoke only in the areas 4 Making and checking signs
provided for smoking. Never smoke while Prohibition of operation and handling by
5
working. unlicensed workers
3) When carrying out any operation, always 6 Safety check before starting work
wear safety shoes and helmet. Do not
Wearing protective goggles
wear loose work clothes, or clothes with 7
(for cleaning or grinding work)
buttons missing.
q Always wear safety glasses when hit- Wearing shielding goggles and protectors
8
ting parts with a hammer. (for welding work)
q Always wear safety glasses when 9 Good physical condition and preparation
grinding parts with a grinder, etc. Precautions against work which you are
4) When carrying out any operation with 2 or 10
not used to or you are used to too much
more workers, always agree on the oper-
ating procedure before starting. Always
inform your fellow workers before starting 2. Preparations for work
any step of the operation. Before starting 1) Before adding oil or making any repairs,
work, hang UNDER REPAIR warning park the machine on hard and level
signs in the operator's compartment. ground, and apply the parking brake and
5) Only qualified workers must carry out work block the wheels or tracks to prevent the
and operation which require license or machine from moving.
qualification. 2) Before starting work, lower the work
6) Keep all tools in good condition, learn the equipment (blade, ripper, bucket, etc.) to
correct way to use them, and use the the ground. If this is not possible, insert
proper ones of them. Before starting work, the lock pin or use blocks to prevent the
thoroughly check the tools, machine, fork- work equipment from falling. In addition,
lift, service car, etc. be sure to lock all the control levers and
hang warning signs on them.
2 95E-5 Series
3) When disassembling or assembling, sup- 8) When removing piping, stop the fuel or oil
port the machine with blocks, jacks, or from spilling out. If any fuel or oil drips
stands before starting work. onto the floor, wipe it up immediately. Fuel
4) Remove all mud and oil from the steps or or oil on the floor can cause you to slip
other places used to get on and off the and can even start fires.
machine. Always use the handrails, lad- 9) As a general rule, do not use gasoline to
ders or steps when getting on or off the wash parts. Do not use it to clean electri-
m a c h i n e . N e v e r j u m p o n o r o ff t h e cal parts, in particular.
machine. If it is impossible to use the 10) Be sure to assemble all parts again in their
handrails, ladders or steps, use a stand to original places. Replace any damaged
provide safe footing. parts and parts which must not be reused
with new parts. When installing hoses and
3. Precautions during work wires, be sure that they will not be dam-
1) Before disconnecting or removing compo- aged by contact with other parts when the
nents of the oil, water, or air circuits, first machine is operated.
release the pressure completely from the 11) When installing high pressure hoses,
circuit. When removing the oil filler cap, a make sure that they are not twisted. Dam-
drain plug, or an oil pressure pickup plug, aged tubes are dangerous, so be
loosen it slowly to prevent the oil from extremely careful when installing tubes for
spurting out. high pressure circuits. In addition, check
2) The coolant and oil in the circuits are hot t h a t c o n n e c t i n g pa r ts a r e c o r r e c t l y
when the engine is stopped, so be careful installed.
not to get scalded. Wait for the oil and 12) When assembling or installing parts,
coolant to cool before carrying out any always tighten them to the specified
work on the oil or water circuits. torques. When installing protective parts
3) Before starting work, stop the engine. such as guards, or parts which vibrate vio-
When working on or around a rotating lently or rotate at high speed, be particu-
part, in particular, stop the engine. When larly careful to check that they are
checking the machine without stopping installed correctly.
the engine (measuring oil pressure, 13) When aligning 2 holes, never insert your
revolving speed, temperature, etc.), take fingers or hand. Be careful not to get your
extreme care not to get rolled or caught in fingers caught in a hole.
rotating parts or moving parts. 14) When measuring hydraulic pressure,
4) Before starting work, remove the leads check that the measuring tools are cor-
from the battery. Always remove the lead rectly assembled.
from the negative () terminal first. 15) Take care when removing or installing the
5) When raising a heavy component (heavier tracks of track-type machines. When
than 25 kg), use a hoist or crane. Before removing the track, the track separates
starting work, check that the slings (wire suddenly, so never let anyone stand at
ropes, chains, and hooks) are free from either end of the track.
damage. Always use slings which have 16) If the engine is operated for a long time in
ample capacity and install them to proper a place which is not ventilated well, you
places. Operate the hoist or crane slowly may suffer from gas poisoning. Accord-
to prevent the component from hitting any ingly, open the windows and doors to ven-
other part. Do not work with any part still tilate well.
raised by the hoist or crane.
6) When removing a cover which is under
internal pressure or under pressure from a
spring, always leave 2 bolts in diagonal
positions. Loosen those bolts gradually
and alternately to release the pressure,
and then remove the cover.
7) When removing components, be careful
not to break or damage the electrical wir-
ing. Damaged wiring may cause electrical
fires.
95E-5 Series 3
4. Precautions for sling work and making

signs
1) Only one appointed worker must make
signs and co-workers must communicate
with each other frequently. The appointed
sign maker must make specified signs
clearly at a place where he is seen well
from the operator's seat and where he can
see the working condition easily. The sign
maker must always stand in front of the
load and guide the operator safely.
q Do not stand under the load.
q Do not step on the load.
2) Check the slings before starting sling
work.
8) When installing wire ropes to an angular
3) Keep putting on gloves during sling work.
load, apply pads to protect the wire ropes.
(Put on leather gloves, if available.)
If the load is slippery, apply proper mate-
4) Measure the weight of the load by the eye
rial to prevent the wire rope from slipping.
and check its center of gravity.
9) Use the specified eyebolts and fix wire
5) Use proper sling according to the weight
ropes, chains, etc. to them with shackles,
of the load and method of slinging. If too
etc.
thick wire ropes are used to sling a light
10) Apply wire ropes to the middle portion of
load, the load may slip and fall.
the hook.
6) Do not sling a load with 1 wire rope alone.
q Slinging near the tip of the hook may
If it is slung so, it may rotate and may slip
cause the rope to slip off the hook
out of the rope. Install 2 or more wire
during hoisting. The hook has the
ropes symmetrically.
k Slinging with 1 rope may cause
maximum strength at the middle por-
tion.
turning of the load during hoisting,
untwisting of the rope, or slipping
of the rope from its original wind-
ing position on the load, which can
result in a dangerous accident.
7) Limit the hanging angle to 60, as a rule.
Do not sling a heavy load with ropes form-
ing a wide hanging angle from the hook.
When hoisting a load with 2 or more
ropes, the force subjected to each rope
will increase with the hanging angle. The
table below shows the variation of allow-
able load in kN {kg} when hoisting is made
with 2 ropes, each of which is allowed to
sling up to 9.8 kN {1,000 kg} vertically, at
various hanging angles. When the 2 ropes 11) Do not use twisted or kinked wire ropes.
sling a load vertically, up to 19.6 kN {2,000 12) When lifting up a load, observe the follow-
kg} of total weight can be suspended. ing.
This weight is reduced to 9.8 kN {1,000 q Wind in the crane slowly until wire
kg} when the 2 ropes make a hanging ropes are stretched. When settling
angle of 120. If the 2 ropes sling a 19.6 the wire ropes with the hand, do not
kN {2,000 kg} load at a lifting angle of grasp them but press them from
150, each of them is subjected to a force above. If you grasp them, your fingers
as large as 39.2 kN {4,000 kg}. may be caught.
q After the wire ropes are stretched,
stop the crane and check the condi-
tion of the slung load, wire ropes, and
pads.
4 95E-5 Series
q If the load is unstable or the wire rope 13) If the hoist stops because of a power fail-
or chains are twisted, lower the load ure, turn the power switch OFF. When
and lift it up again. turning on a switch which was turned OFF
q Do not lift up the load slantingly. by the electric shock prevention earth
13) When lifting down a load, observe the fol- leakage breaker, check that the devices
lowing. related to that switch are not in operation
q When lifting down a load, stop it tem- state.
porarily at 30 cm above the floor, and 14) If you find an obstacle around the hoist,
then lower it slowly. stop the operation.
q Check that the load is stable, and 15) After finishing the work, stop the hoist at
then remove the sling. the specified position and raise the hook
q Remove kinks and dirt from the wire to at least 2 m above the floor. Do not
ropes and chains used for the sling leave the sling installed to the hook.
work, and put them in the specified
place. 7. Selecting wire ropes
1) Select adequate ropes depending on the
5. Precautions for using mobile crane weight of parts to be hoisted, referring to
a Read the Operation and Maintenance the table below.
Manual of the crane carefully in advance
and operate the crane safely. Wire ropes
(Standard Z twist ropes without galvanizing)
6. Precautions for using overhead hoist crane (JIS G3525, No. 6, Type 6X37-A)
k When raising a heavy part (heavier Nominal
Allowable load
than 25 kg), use a hoist, etc. In Disas- diameter of rope
sembly and assembly, the weight of a mm kN ton
part heavier than 25 kg is indicated 10 8.8 0.9
after the mark of 4. 12 12.7 1.3
1) Before starting work, inspect the wire 14 17.3 1.7
ropes, brake, clutch, controller, rails, over
16 22.6 2.3
wind stop device, electric shock preven-
18 28.6 2.9
tion earth leakage breaker, crane collision
20 35.3 3.6
prevention device, and power application
warning lamp, and check safety. 25 55.3 5.6
2) Observe the signs for sling work. 30 79.6 8.1
3) Operate the hoist at a safe place. 40 141.6 14.4
4) Check the direction indicator plates (east, 50 221.6 22.6
west, south, and north) and the directions 60 318.3 32.4
of the control buttons without fail.
5) Do not sling a load slantingly. Do not move a The allowable load is one-sixth of the
the crane while the slung load is swinging. breaking strength of the rope used
6) Do not raise or lower a load while the (Safety coefficient: 6).
crane is moving longitudinally or laterally.
7) Do not drag a sling.
8) When lifting up a load, stop it just after it
leaves the ground and check safety, and
then lift it up.
9) Consider the travel route in advance and
lift up a load to a safe height.
10) Place the control switch on a position
where it will not be an obstacle to work
and passage.
11) After operating the hoist, do not swing the
control switch.
12) Remember the position of the main switch
so that you can turn off the power immedi-
ately in an emergency.
95E-5 Series 5
8. Precautions for disconnecting and con-

necting hoses and tubes in air conditioner
circuit
1) Disconnection
k Collect the air conditioner refrigerant
gas (R134a).
k If the refrigerant gas (R134a) gets in
your eyes, you may lose your sight.
Accordingly, when collecting or adding
it, you must be qualified for handling
the refrigerant and put on protective
goggles.
2) Connection
1] When installing the air conditioner cir-
cuit hoses and tubes, take care that
dirt, dust, water, etc. will not enter
them.
2] When connecting the air conditioner
hoses and tubes, check that O-rings
(1) are fitted to their joints.
3] Check that each O-ring is not dam-
aged or deteriorated.
4] When connecting the refrigerant pip-
ing, apply compressor oil for refriger-
ant (R134a) (DENSO: ND-OIL8,
ZEXEL: ZXL100PG (equivalent to
PAG46)) to its O-rings.
a Example of O-ring (Fitted to every joint of

hoses and tubes)
a For tightening torque, see the precautions for

installation in each section of "Disassembly
and assembly".
6 95E-5 Series
How to read the shop manual 1
q Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one
of them is required, consult KOMATSU distributors.
q Materials and specifications are subject to change without notice.
q Shop manuals are divided into the Chassis volume and Engine volume. For the engine unit, see the
engine volume of the engine model mounted on the machine.
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 dis-
assembly 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.
2. Revision and distribution

Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most
up-to-date information before you start any work.
95E-5 Series 7
3. Filing method
File by the brochures in the correct order of the form number printed in the shop manual composition
table.
q Revised edition mark

When a manual is revised, the ones and tens digits of the form number of each brochure is
increased by 1. (Example: 00, 01, 02 )
q Revisions
Revised brochures are shown in the shop manual composition table.
4. Symbols
Important safety and quality portions are marked with the following symbols so that the shop manual will
be used practically.
Symbol Item Remarks
k Safety Special safety precautions are necessary when performing work.
Special technical precautions or other precautions for preserving stan-

a Caution
dards are necessary when performing work.
4
Weight of parts of component or parts. Caution necessary when
Weight
selecting hoisting wire, or when working posture is important, etc.
3
Tightening Places that require special attention for tightening torque during
torque assembly.
2 Coat Places to be coated with adhesives, etc. during assembly.
5
Oil, coolant Places where oil, etc. must be added, and capacity.
6
Drain Places where oil, etc. must be drained, and quantity to be drained.
5. Units
In this shop manual, the units are indicated with International System of units (SI). For reference, con-
ventionally used Gravitational System of units is indicated in parentheses { }.
8 95E-5 Series
Explanation of terms for maintenance standard 1

The maintenance standard values necessary for judgment of products and parts are described by the follow-
ing terms.
1. Standard size and tolerance

q To be accurate, the finishing size of parts
is a little different from one to another.
q To specify a finishing size of a part, a tem-
porary standard size is set and an allow-
able difference from that size is indicated.
q The above size set temporarily is called
the standard size and the range of differ-
ence from the standard size is called the
tolerance.
q The tolerance with the symbols of + or is
indicated on the right side of the standard
size.
Example:
Standard size Tolerance
0.022
120
0.126
a The tolerance may be indicated in the text

and a table as [standard size (upper limit
of tolerance/lower limit of tolerance)].
Example) 120 (0.022/0.126)
q Usually, the size of a hole and the size of

the shaft to be fitted to that hole are indi-
cated by the same standard size and dif-
ferent tolerances of the hole and shaft.
The tightness of fit is decided by the toler-
ance.
q Indication of size of rotating shaft and hole
and relationship drawing of them
Example:
Tolerance
Standard size
Shaft Hole
0.030 +0.046
60
0.076 +0
95E-5 Series 9
2. Standard clearance and standard value 5. Clearance limit

q The clearance made when new parts are q Parts can be used until the clearance
assembled is called the standard clear- between them is increased to a certain
ance, which is indicated by the range limit. The limit at which those parts cannot
from the minimum clearance to the maxi- be used is called the clearance limit.
mum clearance. q If the clearance between the parts
q When some parts are repaired, the clear- exceeds the clearance limit, they must be
ance is generally adjusted to the standard replaced or repaired.
clearance.
q A value of performance and function of 6. Interference limit
new products or equivalent is called the q The allowable maximum interference
standard value, which is indicated by a between the hole of a part and the shaft of
range or a target value. another part to be assembled is called the
q When some parts are repaired, the value interference limit.
of performance/function is set to the stan- q The interference limit shows the repair
dard value. limit of the part of smaller tolerance.
q If the interference between the parts
3. Standard interference exceeds the interference limit, they must
q When the diameter of a hole of a part be replaced or repaired.
shown in the given standard size and tol-
erance table is smaller than that of the
mating shaft, the difference between those
diameters is called the interference.
q The range (A B) from the difference (A)
between the minimum size of the shaft
and the maximum size of the hole to the
difference (B) between the maximum size
of the shaft and the minimum size of the
hole is the standard interference.
q After repairing or replacing some parts,
measure the size of their hole and shaft
and check that the interference is in the
standard range.
4. Repair limit and allowable value

q The size of a part changes because of
wear and deformation while it is used. The
limit of changed size is called the repair
limit.
q If a part is worn to the repair limit must be
replaced or repaired.
q The performance and function of a prod-
uct lowers while it is used. A value below
which the product can be used without
causing a problem is called the allowable
value.
q If a product is worn to the allowable value,
it must be checked or repaired. Since the
permissible value is estimated from vari-
ous tests or experiences in most cases,
however, it must be judged after consider-
ing the operating condition and customer's
requirement.
10 95E-5 Series
Handling electric equipment and hydraulic component 1

To maintain the performance of the machine over a long period, and to prevent failures or other troubles
before they occur, correct operation, maintenance and inspection, troubleshooting, and repairs must
be carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at
improving the quality of repairs. For this purpose, it gives sections on Handling electric equipment and
Handling hydraulic equipment (particularly gear oil and hydraulic oil).
Points to remember when handling electric

equipment
1. Handling wiring harnesses and connectors
Wiring harnesses consist of wiring connecting
one component to another component, con-
nectors used for connecting and disconnecting
one wire from another wire, and protectors or
tubes used for protecting the wiring.
Compared with other electrical components fit-
ted in boxes or cases, wiring harnesses are
more likely to be affected by the direct effects
of rain, water, heat, or vibration. Furthermore,
during inspection and repair operations, they
are frequently removed and installed again, so
they are likely to suffer deformation or damage.
For this reason, it is necessary to be extremely
careful when handling wiring harnesses.
2. Main failures occurring in wiring harness

1) Defective contact of connectors (defec-
tive contact between male and female)
Problems with defective contact are likely
to occur because the male connector is
not properly inserted into the female con-
nector, or because one or both of the con-
nectors is deformed or the position is not
correctly aligned, or because there is cor-
rosion or oxidization of the contact sur-
faces. The corroded or oxidized contact
surfaces may become shiny again (and
contact may become normal) by connect-
ing and disconnecting the connector about
10 times.
2) Defective crimping or soldering of connec-

tors
The pins of the male and female connec-
tors are in contact at the crimped terminal
or soldered portion, but if there is exces-
sive force brought to bear on the wiring,
the plating at the joint will peel and cause
improper connection or breakage.
95E-5 Series 11
3) Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with
a crane with the wiring still connected, or a
heavy object hits the wiring, the crimping
of the connector may separate, or the sol-
dering may be damaged, or the wiring
may be broken.
4) High-pressure water entering connector

The connector is designed to make it diffi-
cult for water to enter (drip-proof struc-
ture), but if high-pressure water is sprayed
directly on the connector, water may enter
the connector, depending on the direction
of the water jet. Accordingly, take care not
to splash water over the connector. The
connector is designed to prevent water
from entering, but at the same time, if
water does enter, it is difficult for it to be
drained. Therefore, if water should get into
the connector, the pins will be short-cir-
cuited by the water, so if any water gets in,
immediately dry the connector or take
other appropriate action before passing
electricity through it.
5) Oil or dirt stuck to connector

If oil or grease are stuck to the connector
and an oil film is formed on the mating sur-
face between the male and female pins,
the oil will not let the electricity pass, so
there will be defective contact. If there is
oil or grease stuck to the connector, wipe it
off with a dry cloth or blow it dry with com-
pressed air and spray it with a contact
restorer.
a When wiping the mating portion of the
connector, be careful not to use
excessive force or deform the pins.
a If there is oil or water in the com-
pressed air, the contacts will become
even dirtier, so remove the oil and
water from the compressed air com-
pletely before cleaning with com-
pressed air.
12 95E-5 Series
3. Removing, installing, and drying connec-

tors and wiring harnesses
1) Disconnecting connectors
1] Hold the connectors when discon-
necting.
When disconnecting the connectors,
hold the connectors. For connectors
held by a screw, loosen the screw
fully, then hold the male and female
connectors in each hand and pull
apart. For connectors which have a
lock stopper, press down the stopper
with your thumb and pull the connec-
tors apart.
a Never pull with one hand.
2] When removing from clips

q Both of the connector and clip have
stoppers, which are engaged with
each other when the connector is
installed.
q When removing a connector from a

clip, pull the connector in a parallel
direction to the clip for removing stop-
pers.
a If the connector is twisted up and
down or to the left or right, the
housing may break.
3] Action to take after removing connec-

tors
After removing any connector, cover it
with a vinyl bag to prevent any dust,
dirt, oil, or water from getting in the
connector portion.
a If the machine is left disassem-
bled for a long time, it is particu-
larly easy for improper contact to
occur, so always cover the con-
nector.
95E-5 Series 13
2) Connecting connectors
1] Check the connector visually.
Check that there is no oil, dirt, or
water stuck to the connector pins
(mating portion).
Check that there is no deformation,
defective contact, corrosion, or dam-
age to the connector pins.
Check that there is no damage or
breakage to the outside of the con-
nector.
a If there is any oil, water, or dirt
stuck to the connector, wipe it off
with a dry cloth. If any water has
got inside the connector, warm
the inside of the wiring with a
dryer, but be careful not to make
it too hot as this will cause short
circuits.
a If there is any damage or break-
age, replace the connector.
2] Fix the connector securely.
Align the position of the connector
correctly, and then insert it securely.
For connectors with the lock stopper,
push in the connector until the stop-
per clicks into position.
3] Correct any protrusion of the boot and
any misalignment of the wiring har-
ness.
For connectors fitted with boots, cor-
rect any protrusion of the boot. In
addition, if the wiring harness is mis-
aligned, or the clamp is out of posi-
tion, adjust it to its correct position.
a If the connector cannot be cor-
rected easily, remove the clamp
and adjust the position.
q If the connector clamp has been
removed, be sure to return it to
its original position. Check also
that there are no loose clamps.
14 95E-5 Series
3) Heavy duty wire connector (DT 8-pole, 12- q Disconnection q Connection (Example of
pole) incomplete setting of (a))
Disconnection (Left of figure)
While pressing both sides of locks (a)
and (b), pull out female connector (2).
Connection (Right of figure)
1] Push in female connector (2) horizon-
tally until the lock clicks.
Arrow: 1)
2] Since locks (a) and (b) may not be set
completely, push in female connector
(2) while moving it up and down until
the locks are set normally.
Arrow: 1), 2), 3)
a Right of figure: Lock (a) is pulled
down (not set completely) and
lock (b) is set completely.
(1): Male connector
(2): Female connector
(a), (b): Locks
95E-5 Series 15
4) Drying wiring harness

If there is any oil or dirt on the wiring har-
ness, wipe it off with a dry cloth. Avoid
washing it in water or using steam. If the
connector must be washed in water, do
not use high-pressure water or steam
directly on the wiring harness. If water
gets directly on the connector, do as fol-
lows.
1] Disconnect the connector and wipe
off the water with a dry cloth.
a If the connector is blown dry with
compressed air, there is the risk
that oil in the air may cause
defective contact, so remove all
oil and water from the com-
pressed air before blowing with
air.
2] Dry the inside of the connector with a
dryer.
If water gets inside the connector, use
a dryer to dry the connector.
a Hot air from the dryer can be
used, but regulate the time that
the hot air is used in order not to
make the connector or related
parts too hot, as this will cause
deformation or damage to the
connector.
3] Carry out a continuity test on the con-
nector.
After drying, leave the wiring harness
disconnected and carry out a continu-
ity test to check for any short circuits
between pins caused by water.
a After completely drying the con-
n e c t o r, b l o w i t w i t h c o n ta c t
restorer and reassemble.
16 95E-5 Series
4. Handling controller
1) The controller contains a microcomputer
and electronic control circuits. These con-
trol all of the electronic circuits on the
machine, so be extremely careful when
handling the controller.
2) Do not place objects on top of the control-
ler.
3) Cover the control connectors with tape or
a vinyl bag. Never touch the connector
contacts with your hand.
4) During rainy weather, do not leave the
controller in a place where it is exposed to
rain.
5) Do not place the controller on oil, water, or
soil, or in any hot place, even for a short
time. (Place it on a suitable dry stand).
6) Precautions when carrying out arc welding
When carrying out arc welding on the
body, disconnect all wiring harness con-
nectors connected to the controller. Fit an
arc welding ground close to the welding
point.
5. Points to remember when troubleshooting

electric circuits
1) Always turn the power OFF before discon-
necting or connecting connectors.
2) Before carrying out troubleshooting, check
that all the related connectors are properly
inserted.
a Disconnect and connect the related
connectors several times to check.
3) Always connect any disconnected con-
nectors before going on to the next step.
a If the power is turned ON with the
connectors still disconnected, unnec-
essary abnormality displays will be
generated.
4) When carrying out troubleshooting of cir-
cuits (measuring the voltage, resistance,
continuity, or current), move the related
wiring and connectors several times and
check that there is no change in the read-
ing of the tester.
a If there is any change, there is proba-
bly defective contact in that circuit.
95E-5 Series 17
Points to remember when handling hydraulic equipment

With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt
(foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling
hydraulic equipment, it is necessary to be particularly careful.
1. Be careful of the operating environment.

Avoid adding hydraulic oil, replacing filters, or
repairing the machine in rain or high winds, or
places where there is a lot of dust.
2. Disassembly and maintenance work in the

field
If disassembly or maintenance work is carried
out on hydraulic equipment in the field, there is
danger of dust entering the equipment. It is
also difficult to check the performance after
repairs, so it is desirable to use unit exchange.
Disassembly and maintenance of hydraulic
equipment should be carried out in a specially
prepared dustproof workshop, and the perfor-
mance should be checked with special test
equipment.
3. Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from
entering. If the opening is left open or is
blocked with a rag, there is danger of dirt
entering or of the surrounding area being
made dirty by leaking oil so never do this. Do
not simply drain oil out onto the ground, but
collect it and ask the customer to dispose of it,
or take it back with you for disposal.
4. Do not let any dirt or dust get in during

refilling operations
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers. If an oil clean-
ing device is used, it is possible to filter out the
dirt that has collected during storage, so this is
an even more effective method.
18 95E-5 Series
5. Change hydraulic oil when the temperature

is high
When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be
drained out easily from the circuit together with
the oil, so it is best to change the oil when it is
still warm. When changing the oil, as much as
possible of the old hydraulic oil must be
drained out. (Drain the oil from the hydraulic
tank; also drain the oil from the filter and from
the drain plug in the circuit.) If any old oil is left,
the contaminants and sludge in it will mix with
the new oil and will shorten the life of the
hydraulic oil.
6. Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit. Normally, flushing is
carried out twice: primary flushing is carried
out with flushing oil, and secondary flushing is
carried out with the specified hydraulic oil.
7. Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the
machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil cir-
cuit. The oil cleaning equipment is used to
remove the ultra fine (about 3 m) particles that
the filter built in the hydraulic equipment can-
not remove, so it is an extremely effective
device.
95E-5 Series 19
Connectors newly used for Tier 3 engines

1. Slide lock type 2. Pull lock type (PACKARD-2)
(FRAMATOME-3, FRAMATOME-2) q 107 170, 12V140 engine
q 107 170, 12V140 engines q Various temperature sensors
q Various pressure sensors and NE Example)
speed sensor Intake air temperature sensor in
Examples) intake manifold: TIM
Intake air pressure in intake manifold: Fuel temperature sensor: TFUEL
PIM (125, 170, 12V140 engines) Oil temperature sensor: TOIL
Oil pressure sensor: POIL Coolant temperature sensor: TWTR,
(125, 170, 12V140 engines) etc.
Oil pressure switch Disconnect the connector by pulling lock
(107, 114 engines) (B) (on the wiring harness side) of connec-
Ne speed sensor of flywheel housing: tor (2) outward.
NE (107 170, 12V140 engines)
Ambient pressure sensor: PAMB
(125, 170, 12V140 engines)
Disconnect connector (1) according to the fol-

lowing procedure.
1) Slide lock (L1) to the right.
2) While pressing lock (L2), pull out connec-
tor (1) toward you.
a Even if lock (L2) is pressed, connec-
tor (1) cannot be pulled out toward
you, if part A does not float. In this
case, float part A with a small screw-
driver while press lock (L2), and then
pull out connector (1) toward you.
20 95E-5 Series
3. Push lock type

q 107, 114 engines
Example)
Fuel pressure sensor in common rail
(BOSCH-03)
Disconnect connector (3) according to the fol-

lowing procedure.
1) While pressing lock (C), pull out connector
(3) in the direction of the arrow.
q 114 engine
q 107, 114 engine

Example)
Intake air pressure/temperature sensor in
intake manifold
(SUMITOMO-04)
3) While pressing lock (D), pull out connector

(4) in the direction of the arrow.
q 107 engine
a If the lock is on the underside, use

flat-head screwdriver [1] since you
cannot insert your fingers.
2) While pressing up lock (C) of the connec-
tor with flat-head screwdriver [1], pull out
connector (3) in the direction of the arrow.
95E-5 Series 21
q 125 170, 12V140 engine 4. Turn-housing type (Round green connector)

4) While pressing lock (E) of the connector, q 140 engine
pullout connector (5) in the direction of the Example)
arrow. Intake air pressure sensor in intake mani-
fold (CANNON-04): PIM etc.
Example)
Fuel pressure in common rail: PFUEL etc. 1) Disconnect connector (6) according to the
(AMP-3) following procedure.
1] Turn housing (H1) in the direction of
the arrow.
a When connector is unlocked,
housing (H1) becomes heavy to
turn.
2] Pull out housing (H1) in the direction
of the arrow.
a Housing (H1) is left on the wiring har-
ness side.
Example)
Injection pressure control valve of fuel
supply pump: PCV (SUMITOMO-2)
2) Connect the connector according to the

following procedure.
1] Insert the connector to the end, while
setting its groove.
2] Turn housing (H1) in the direction of
the arrow until it clicks.
Example)
Speed sensor of fuel supply pump:
G (SUMITOMO-3)
a Pull the connector straight up.
22 95E-5 Series
How to read electric wire code 1

a The information about the wires unique to each machine model is described in Troubleshooting section,
Relational information of troubleshooting.
In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by sym-
bols. The electric wire code is helpful in understanding the electric circuit diagram.
Example: AEX 0.85 L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nomi-
nal No. of 0.85
Indicates color of wire by color code.
Color codes are shown in Table 3.
Indicates size of wire by nominal No.

Size (Nominal No.) is shown in Table 2.
Indicates type of wire by symbol.

Type, symbol, and material of wire are shown in Table 1.
(Since AV and AVS are classified by size (nominal No.), they are not indi-
cated.)
1. Type, symbol, and material

AV and AVS are different in only thickness and outside diameter of the cover. AEX is similar to AV in
thickness and outside diameter of AEX and different from AV and AVS in material of the cover.
(Table 1)
Using
Sym-
Type Material temperature Example of use
bol
range (C)
Low-voltage Conduc- Annealed copper for elec-
General wiring
wire for AV tor tric appliance
(Nominal No. 5 and above)
automobile Insulator Soft polyvinyl chloride
Thin-cover Conduc- Annealed copper for elec- 30 to +60
low-voltage tor tric appliance General wiring
AVS
wire for (Nominal No. 3 and below)
Insulator Soft polyvinyl chloride
automobile
Heat-resis- Conduc- Annealed copper for elec-
General wiring in extremely
tant low-volt- tor tric appliance
AEX 50 to +110 cold district, wiring at high-tem-
age wire for Heat-resistant crosslinked
Insulator perature place
automobile polyethylene
95E-5 Series 23
2. Dimensions
(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5
Number of
strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32
eter of strand
Conductor
Sectional
0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
area (mm2)
d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0
AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6
Cov-
AV Standard 4.6
er D
AEX Standard 2.0 2.2 2.7 3.0 3.1 3.8 4.6
Nominal No. 8 15 20 30 40 50 60 85 100

Number of
strands/Diam- 50/0.45 84/0.45 41/0.80 70/0.80 85/0.80 108/0.80 127/0.80 169/0.80 217/0.80
eter of strand
Conductor
Sectional
7.95 13.36 20.61 35.19 42.73 54.29 63.84 84.96 109.1
area (mm2)
d (approx.) 3.7 4.8 6.0 8.0 8.6 9.8 10.4 12.0 13.6
AVS Standard
Cov-
AV Standard 5.5 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
er D
AEX Standard 5.3 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
f of nominal No. denotes flexible.
24 95E-5 Series
3. Color codes table
(Table 3)
Color Code Color of wire Color Code Color of wire
B Black LgW Light green & White
Br Brown LgY Light green & Yellow
BrB Brown & Black LR Blue & Red
BrR Brown & Red LW Blue & White
BrW Brown & White LY Blue & Yellow
BrY Brown & Yellow O Orange
Ch Charcoal P Pink
Dg Dark green R Red
G Green RB Red & Black
GB Green & Black RG Red & Green
GL Green & Blue RL Red & Blue
Gr Gray RW Red & White
GR Green & Red RY Red & Yellow
GW Green & White Sb Sky Blue
GY Green & Yellow Y Yellow
L Blue YB Yellow & Black
LB Blue & Black YG Yellow &Green
Lg Light green YL Yellow & Blue
LgB Light green & Black YR Yellow & Red
LgR Light green & Red YW Yellow & White
Remarks: In a color code consisting of 2 colors, the first color is the color of the background and
the second color is the color of the marking.
Example: GW means that the background is Green and marking is White.
4. Types of circuits and color codes
(Table 4)
Type of wire AVS or AV AEX
Charge R WG R
Ground B B
Start R R
Light RW RB RY RG RL D
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
Br BrW BrR BrY BrB
circuit
Lg LgR LgY LgB LgW
O
Others Gr
P
Sb
Dg
Ch
95E-5 Series 25
Precautions when carrying out operation 1

[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general
precautions given below when carrying out the operation.]
1. Precautions when carrying out removal work

q If the coolant contains antifreeze, dispose of it correctly.
q After disconnecting hoses or tubes, cover them or fit plugs to prevent dirt or dust from entering.
q When draining oil, prepare a container of adequate size to catch the oil.
q Confirm the match marks showing the installation position, and make match marks in the necessary
places before removal to prevent any mistake when assembling.
q To prevent any excessive force from being applied to the wiring, always hold the connectors when dis-
connecting the connectors. Do not pull the wires.
q Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.
q Check the number and thickness of the shims, and keep in a safe place.
q When raising components, be sure to use lifting equipment of ample strength.
q When using forcing screws to remove any components, tighten the forcing screws uniformly in turn.
q Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from
entering after removal.
a Precautions when handling piping during disassembly
Fit the following plugs into the piping after disconnecting it during disassembly operations.
1) Face seal type hoses and tubes
Nominal
Plug (nut end) Sleeve nut (elbow end)
number
02 07376-70210 02789-20210
03 07376-70315 02789-20315
04 07376-70422 02789-20422
05 07376-70522 02789-20522
06 07376-70628 02789-20628
10 07376-71034 07221-21034
12 07376-71234 07221-21234
2) Split flange type hoses and tubes

Nominal
Flange (hose end) Sleeve head (tube end) Split flange
number
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500
3) If the part is not under hydraulic pressure, the following corks can be used.
Nominal Dimensions
Part Number
number D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34
26 95E-5 Series
2. Precautions when carrying out installation work

q Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
q Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any.
q Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
q Bend the cotter pins and lock plates securely.
q When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded por-
tion with 2 3 drops of adhesive.
q When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is
no dirt or damage, then coat uniformly with gasket sealant.
q Clean all parts, and correct any damage, dents, burrs, or rust.
q Coat rotating parts and sliding parts with engine oil.
q When press fitting parts, coat the surface with anti-friction compound (LM-P).
q After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
q When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
securely.
q When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align
the direction of the hook.
q When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
a When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other
hydraulic equipment removed for repair, always bleed the air as follows:
1) Start the engine and run at low idle.
2) Operate the work equipment control lever to operate the hydraulic cylinder 4 5 times, stopping the
cylinder 100 mm from the end of its stroke.
3) Next, operate the hydraulic cylinder 3 4 times to the end of its stroke.
4) After doing this, run the engine at normal speed.
a When using the machine for the first time after repair or long storage, follow the same procedure.
3. Precautions when completing the operation

1) Refilling with coolant, oil and grease
q If the coolant has been drained, tighten the drain valve, and add coolant to the specified level.
Run the engine to circulate the coolant through the system. Then check the coolant level
again.
q If the hydraulic equipment has been removed and installed again, add engine oil to the speci-
fied level. Run the engine to circulate the oil through the system. Then check the oil level
again.
q If the piping or hydraulic equipment have been removed, always bleed the air from the system
after reassembling the parts.
a For details, see Testing and adjusting, Bleeding air.
q Add the specified amount of grease (molybdenum disulphide grease) to the work equipment
parts.
2) Checking cylinder head and manifolds for looseness
Check the cylinder head and intake and exhaust manifold for looseness.
If any part is loosened, retighten it.
q For the tightening torque, see Disassembly and assembly.
3) Checking engine piping for damage and looseness
Intake and exhaust system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for air
suction and exhaust gas leakage.
If any part is loosened or damaged, retighten or repair it.
Cooling system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for
coolant leakage.
Fuel system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel
leakage.
95E-5 Series 27
4) Checking muffler and exhaust pipe for damage and looseness

1] Visually check the muffler, exhaust pipe and their mounting parts for a crack and damage.
If any part is damaged, replace it.
2] Check the mounting bolts and nuts of the muffler, exhaust pipe and their mounting parts for
looseness.
If any bolt or nut is loosened, retighten it.
5) Checking muffler function
Check the muffler for abnormal sound and sound different from that of a new muffler.
If any abnormal sound is heard, repair the muffler, referring to Troubleshooting and Disassembly
and assembly.
28 95E-5 Series
Method of disassembling and connecting push-pull type coupler 1

k Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to
release the residual pressure from the hydraulic tank.
k Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly, prepare an oil receiving container.
Type 1
1. Disconnection
1) Hold adapter (1) and push hose joint (2)
into mating adapter (3). (Fig. 1)
a The adapter can be pushed in about
3.5 mm.
a Do not hold rubber cap portion (4).
2) After hose joint (2) is pushed into adapter
(3), press rubber cap portion (4) against
adapter (3) until it clicks. (Fig. 2)
3) Hold hose adapter (1) or hose (5) and pull
it out. (Fig. 3)
a Since some hydraulic oil flows out,
prepare an oil receiving container.
2. Connection
1) Hold hose adapter (1) or hose (5) and
insert it in mating adapter (3), aligning
them with each other. (Fig. 4)
a Do not hold rubber cap portion (4).
2) After inserting the hose in the mating
adapter perfectly, pull it back to check its
connecting condition. (Fig. 5)
a When the hose is pulled back, the
rubber cap portion moves toward the
hose about 3.5 mm. This does not
indicate abnormality, however.
95E-5 Series 29
Type 2
1. Disconnection
1) Hold the tightening portion and push body
(7) straight until sliding prevention ring (6)
contacts contact surface (a) of the hexag-
onal portion at the male end. (Fig. 6)
2) While holding the condition of Step 1), turn
lever (8) to the right (clockwise). (Fig. 7)
3) While holding the condition of Steps 1)
and 2), pull out whole body (7) to discon-
nect it. (Fig. 8)
2. Connection
q Hold the tightening portion and push body
contacts contact surface (a) of the hexag-
30 95E-5 Series
Type 3
1. Disconnection
1) Hold the tightening portion and push body
contacts contact surface (b) of the hexag-
2) While holding the condition of Step 1),
push cover (10) straight until it contacts
contact surface (b) of the hexagonal por-
tion at the male end. (Fig. 11)
3) While holding the condition of Steps 1)
and 2), pull out whole body (9) to discon-
nect it. (Fig. 12)
2. Connection
q Hold the tightening portion and push body
(9) straight until the sliding prevention ring
contacts contact surface (b) of the hexag-
95E-5 Series 31
Standard tightening torque table 1

1. Table of tightening torques for bolts and nuts
a Unless there are special instructions, tighten metric nuts and bolts to the torque below. (When using
torque wrench)
a The following table corresponds to the bolts in Fig. A.
Thread diameter of bolt Width across flats Tightening torque

mm mm Nm kgm
6 10 11.8 14.7 1.2 1.5
8 13 27 34 2.8 3.5
10 17 59 74 6.0 7.5
12 19 98 123 10.0 12.5
14 22 153 190 15.5 19.5
16 24 235 285 23.5 29.5
18 27 320 400 33.0 41.0
20 30 455 565 46.5 58.0
22 32 610 765 62.5 78.0
24 36 785 980 80.0 100.0
27 41 1,150 1,440 118 147
30 46 1,520 1,910 155 195
33 50 1,960 2,450 200 250
36 55 2,450 3,040 250 310
39 60 2,890 3,630 295 370
a The following table corresponds to the bolts in Fig. B.

mm mm Nm kgm
6 10 5.9 9.8 0.6 1.0
8 13 13.7 23.5 1.4 2.4
10 14 34.3 46.1 3.5 4.7
12 27 74.5 90.2 7.6 9.2
a Fig. A a Fig. B
32 95E-5 Series
2. Table of tightening torques for split flange bolts

a Unless there are special instructions, tighten split flange bolts to the torque below.

mm mm Nm kgm
10 14 59 74 6.0 7.5
12 17 98 123 10.0 12.5
16 22 235 285 23.5 29.5
3. Table of tightening torques for O-ring boss piping joints

a Unless there are special instructions, tighten O-ring boss piping joints to the torque below.
Thread diameter Width across flats Tightening torque Nm {kgm}

Nominal No.
mm mm Range Target
02 14 35 63 { 3.5 6.5} 44 { 4.5}
03,04 20 Varies depending 84 132 { 8.5 13.5} 103 {10.5}
05,06 24 on type of connec- 128 186 {13.0 19.0} 157 {16.0}
10,12 33 tor. 363 480 {37.0 49.0} 422 {43.0}
14 42 746 1,010 {76.0 103} 883 {90.0}
4. Table of tightening torques for O-ring boss plugs

a Unless there are special instructions, tighten O-ring boss plugs to the torque below.
Nominal Thread diameter Width across flats Tightening torque Nm {kgm}

No. mm mm Range Target
08 8 14 5.88 8.82 {0.6 0.9} 7.35 {0.75}
10 10 17 9.81 12.74 {1.0 1.3} 11.27 {1.15}
12 12 19 14.7 19.6 {1.5 2.0} 17.64 {1.8}
14 14 22 19.6 24.5 {2.0 2.5} 22.54 {2.3}
16 16 24 24.5 34.3 {2.5 3.5} 29.4 {3.0}
18 18 27 34.3 44.1 {3.5 4.5} 39.2 {4.0}
20 20 30 44.1 53.9 {4.5 5.5} 49.0 {5.0}
24 24 32 58.8 78.4 {6.0 8.0} 68.6 {7.0}
30 30 32 93.1 122.5 { 9.5 12.5} 107.8 {11.0}
33 33 107.8 147.0 {11.0 15.0} 127.4 {13.0}
36 36 36 127.4 176.4 {13.0 18.0} 151.9 {15.5}
42 42 181.3 240.1 {18.5 24.5} 210.7 {21.5}
52 52 274.4 367.5 {28.0 37.5} 323.4 {33.0}
95E-5 Series 33
5. Table of tightening torques for hoses (taper seal type and face seal type)
a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the
torque below.
a Apply the following torque when the threads are coated (wet) with engine oil.
Tightening torque Nm {kgm} Taper seal Face seal

Nominal Width Nominal No. -
No. of across Thread diame-
Thread size Number of
Range Target ter (mm) (Ref-
hose flats (mm) threads, type of
erence)
thread
34 54 { 3.5 5.5} 9/16-18UN 14.3
02 19 44 { 4.5}
34 63 { 3.5 6.5} 14
22 54 93 { 5.5 9.5} 74 { 7.5} 11/16-16UN 17.5
03
24 59 98 { 6.0 10.0} 78 { 8.0} 18
04 27 84 132 { 8.5 13.5} 103 {10.5} 22 13/16-16UN 20.6
05 32 128 186 {13.0 19.0} 157 {16.0} 24 1-14UNS 25.4
06 36 177 245 {18.0 25.0} 216 {22.0} 30 1-3/16-12UN 30.2
(10) 41 177 245 {18.0 25.0} 216 {22.0} 33
(12) 46 197 294 {20.0 30.0} 245 {25.0} 36
(14) 55 246 343 {25.0 35.0} 294 {30.0} 42
6. Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts)
a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114
engine series to the torque below.
Tightening torque
Thread size
Bolts and nuts
mm Nm kgm
6 10 2 1.02 0.20
8 24 4 2.45 0.41
10 43 6 4.38 0.61
12 77 12 7.85 1.22
14
7. Table of tightening torques for 102, 107 and 114 engine series (Eye joints)
a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine
series to the torque below.
Thread size Tightening torque

mm Nm kgm
6 82 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
34 95E-5 Series
8. Table of tightening torques for 102, 107 and 114 engine series (Taper screws)
a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114
engine series to the torque below.
Thread size Tightening torque

inch Nm kgm
1/16 31 0.31 0.10
1/8 82 0.81 0.20
1/4 12 2 1.22 0.20
3/8 15 2 1.53 0.20
1/2 24 4 2.45 0.41
3/4 36 5 3.67 0.51
1 60 9 6.12 0.92
95E-5 Series 35
Conversion table 1
Method of using the conversion table
The conversion table in this section is provided to enable simple conversion of figures. For details of the
method of using the conversion table, see the example given below.
Example: Method of using the conversion table to convert from millimeters to inches
1. Convert 55 mm into inches.

1) Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a hori-
zontal line from (A).
2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down
from (B).
3) Take the point where the 2 lines cross as (C). This point (C) gives the value when converting from
millimeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.

1) The number 550 does not appear in the table, so divide it by 10 (move the decimal point one place
to the left) to convert it to 55 mm.
2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal
point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
Millimeters to inches (B)

1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
(C)
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
(A)
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
36 95E-5 Series
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
Liters to U.S. Gallons

1 l = 0.2642 U.S.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
95E-5 Series 37
Liters to U.K. Gallons

1 l = 0.21997 U.K.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.699 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
kgm to ft.lb
1 kgm = 7.233 ft.lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
38 95E-5 Series
kg/cm2 to lb/in2
1 kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1,010 1,024 1,038 1,053 1,067 1,081 1,095 1,109 1,124
80 1,138 1,152 1,166 1,181 1,195 1,209 1,223 1,237 1,252 1,266
90 1,280 1,294 1,309 1,323 1,337 1,351 1,365 1,380 1,394 1,408
100 1,422 1,437 1,451 1,465 1,479 1,493 1,508 1,522 1,536 1,550
110 1,565 1,579 1,593 1,607 1,621 1,636 1,650 1,664 1,678 1,693
120 1,707 1,721 1,735 1,749 1,764 1,778 1,792 1,806 1,821 1,835
130 1,849 1,863 1,877 1,892 1,906 1,920 1,934 1,949 1,963 1,977
140 1,991 2,005 2,020 2,034 2,048 2,062 2,077 2,091 2,105 2,119
150 2,134 2,148 2,162 2,176 2,190 2,205 2,219 2,233 2,247 2,262
160 2,276 2,290 2,304 2,318 2,333 2,347 2,361 2,375 2,389 2,404
170 2,418 2,432 2,446 2,460 2,475 2,489 2,503 2,518 2,532 2,546
180 2,560 2,574 2,589 2,603 2,617 2,631 2,646 2,660 2,674 2,688
190 2,702 2,717 2,731 2,745 2,759 2,773 2,788 2,802 2,816 2,830
200 2,845 2,859 2,873 2,887 2,901 2,916 2,930 2,944 2,958 2,973
210 2,987 3,001 3,015 3,030 3,044 3,058 3,072 3,086 3,101 3,115
220 3,129 3,143 3,158 3,172 3,186 3,200 3,214 3,229 3,243 3,257
230 3,271 3,286 3,300 3,314 3,328 3,343 3,357 3,371 3,385 3,399
240 3,414 3,428 3,442 3,456 3,470 3,485 3,499 3,513 3,527 3,542
95E-5 Series 39
Temperature
Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centi-
grade temperature reading or vice versa is to enter the accompanying table in the center (boldface column)
of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahren-
heit temperatures and read the corresponding Centigrade temperature in the column at the left.
When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centi-
grade values, and read the corresponding Fahrenheit temperature on the right.
1C = 33.8F
C F C F C F C F
40.4 40 40.0 11.7 11 51.8 7.8 46 114.8 27.2 81 177.8
37.2 35 31.0 11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
34.4 30 22.0 10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
31.7 25 13.0 10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
28.9 20 4.0 9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
28.3 19 2.2 8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

27.8 18 0.4 8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
27.2 17 1.4 7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
26.7 16 3.2 7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
26.1 15 5.0 6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
25.6 14 6.8 6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

25.0 13 8.6 5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
24.4 12 10.4 5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
23.9 11 12.2 4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
23.3 10 14.0 3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
22.8 9 15.8 3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

22.2 8 17.6 2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
21.7 7 19.4 2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
21.1 6 21.2 1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
20.6 5 23.0 1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
20.0 4 24.8 0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

19.4 3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
18.9 2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
18.3 1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
40 95E-5 Series
SEN02122-00
2006 KOMATSU
All Rights Reserved
42
SEN02124-00
ENGINE 1SHOP MANUAL
95E-5 Series
01 Specification 1
Specification and technical data
Outline.................................................................................................................................................. 2
Specifications ....................................................................................................................................... 4
General view ........................................................................................................................................ 5
Weight table ......................................................................................................................................... 8
Engine performance curves ................................................................................................................. 9
95E-5 Series 1
SEN02124-00 01 Specification
Outline 1
1. Applicable machine
Engine Engine serial No. Machine models

SAA4D95LE-5 PC138US-8, PC138USLC-8 Hydraulic excavator
2 95E-5 Series
2. Outline of direct injection engine
q The engine has passed strict emission regula- 3) Other features

tions (EPA Regulations of USA, Regulations of q Noise is reduced by improving the piston
EU and Construction machinery regulations of shape and float-mounting the head cover.
Japan) and attained a small size, light weight, q Reliability and durability of the engine are
high output, low fuel consumption, low noise, increased with the development technolo-
high reliability and high durability, and is suit- gies based on the long experience and
able various construction machinery and achievement in development of construc-
industrial machinery. tion machinery and industrial engines.
q The engine is an in-line, vertical, water-cooled,

direct fuel injection and 4-stroke diesel engine 3. Outline of SAA4D95LE-5 engine
which has the following features.
q The SAA4D95LE-5 engine is based on the
1) Small-sized and light-weight engine SAA4D95LE-3 engine having a good record
q Since no liners are used in the engine and meets the 3rd emission regulation (Tier 3)
block, the distance between the cylinders by employing the high-pressure common rail
is reduced, thus the overall length of the injection system and improving the combustion
engine is reduced. chamber etc.
q The stroke bore ratio is as large as 115 The SAA4D95LE-5 engine is made by improv-
mm/95 mm. The overall height of the ing the SAA4D95LE-3 engine in the following
engine is reduced, however, by reducing items.
the distance between the big end center
and small end center of the connecting 1) Employment of high-pressure common rail fuel
rod. injection system
q The heads of the cylinder head and cylin- q Low emission and low noise are attained
der block are thinned and light-weighted and good combustion is maintained by
but their strength is maintained. high-pressure injection, flexibility in the
q Each part is designed economically for injection timing and multiple injection.
weight reduction by applying reliability
analysis technologies. 2) Improvement of combustion chamber
q Production of nitrogen oxides (NOx) in the
2) High performance engine exhaust gas is reduced by controlling the
q Combustion efficiency is improved and early combustion with the 2-stage com-
cleaner exhaust ga s is obta ined by bustion concept. Fuel is mixed with more
designing the air intake port of less suc- air and burnt well in the late combustion
tion resistance and employing the 2-stage period. As a result, less smoke is emitted.
combustion chamber.
q Friction loss horsepower is reduced by 3) Improvement of turbocharger
light-weighting the main moving parts and q The turbocharger of a high pressure ratio
setting the capacity of the auxiliary com- is employed.
ponents (water pump and oil pump) to
proper level.
q Weight, noise and vibration are reduced
by setting the clearance between the pis-
ton and cylinder properly.
95E-5 Series 3
Specifications 1
Engine name SAA4D95LE-5

Machine models PC138US-8, PC138USLC-8
Number of cylinders Bore Stroke mm 4 95 115
Total displacement l{cc} 3.260 {3,260}
Firing order 1243
Overall length mm 994
Dimensions
Overall width mm 714

Overall height (excluding exhaust pipe) mm
Overall height (including exhaust pipe) mm 1,219
72.1 {96.6}/2,200
Rated output kW{HP}/rpm
(Gross)
358 {36.5}/1,500
Max. torque Nm{kgm}/rpm
Performance
(Gross)
No-load max. speed
rpm 2,300 60
(High idle speed)
No-load min. speed
rpm 1,100 50
(Low idle speed)
g/kWh
Fuel consumption ratio at rated point 239 {178}
{g/HPh}
Dry weight kg 332
Fuel supply pump Bosch CP1H-OHW (HPCR)
Governor Electronic control type
Quantity of lubricating oil (Refill capacity) l 11 (12)
Quantity of coolant l (Engine side: 4.5)
Alternator 24 V, 35 A
Starting motor 24 V, 4.5 kW
Battery 12 V, 64 Ah 2
Turbocharger TD04L
Air compressor
Others With air-cooled aftercooler
4 95E-5 Series
General view 1
Left side view of engine
a The shape is subject to machine models.
1. Center of crankshaft
2. Rear face of flywheel housing
95E-5 Series 5
Front view of engine
1. Center of crankshaft
2. Center of cylinder
6 95E-5 Series
Dimensions table
Unit: mm
Dimension of each part
Engine Machine model
A B C D E F G H J
PC138US-8,
SAA4D95LE-5 825 169 994 312 907 1,219 382 332 714
PC138USLC-8
a These dimensions are given for reference when the engine is set on a test bench.
95E-5 Series 7
Weight table 1
Unit: kg
No. Item Main parts SAA4D95LE-5
1 Turbocharger TD04L 5
2 Cylinder head assembly Cylinder head, valve, valve spring 30
Cylinder block, main metal block,
3 Cylinder block assembly 71
cylinder liner
4 Gear case (front cover) 2.6
5 Oil pan 4.4
6 Flywheel assembly Flywheel ring gear 26.6
7 Flywheel housing assembly 25
8 Crankshaft assembly Crankshaft, crank gear 26.1
9 Camshaft assembly Camshaft, cam gear, thrust plate 5.2
Piston and connecting rod Piston, piston ring, piston pin,
10 2.4 4
assembly connecting rod
11 Oil pump 0.6
12 Supply pump 6.1
13 Water pump 7.4
24 V, 35 A 4.7
14 Alternator
24 V, 60 A 6.3
15 Starting motor 24 V, 4.5 kW 8.5
16 Air compressor
17 Aftercooler assembly
8 95E-5 Series
Engine performance curves 1
Engine Engine serial No. Machine model Page

SAA4D95LE-5 PC138US-8, PC138USLC-8 10
95E-5 Series 9
Rated output: 72.1 kW {96.6 HP}/2,200 rpm (Gross)

Max. torque: 358 Nm {36.5 kgm}/1,500 rpm (Gross)
10 95E-5 Series
SEN02124-00
2006 KOMATSU
All Rights Reserved
12
SEN02126-00
ENGINE 1SHOP MANUAL
95E-5 Series
10 Structure, function and

maintenance standard 1
Structure, function and maintenance
standard, Part 1
General structure ............................................................................................................................................ 4
Air intake and exhaust system ........................................................................................................................ 6
Air intake and exhaust unit................................................................................................................... 6
Air cleaner ............................................................................................................................................ 8
Turbocharger...................................................................................................................................... 10
Muffler ................................................................................................................................................ 13
Engine unit .................................................................................................................................................... 14
Cylinder head ..................................................................................................................................... 14
Cylinder block..................................................................................................................................... 16
Cylinder .............................................................................................................................................. 19
Main moving parts .............................................................................................................................. 20
95E-5 Series 1
SEN02126-00 10 Structure, function and maintenance standard
Crankshaft .......................................................................................................................................... 22
Camshaft ............................................................................................................................................ 23
Piston, piston ring and piston pin ....................................................................................................... 24
Connecting rod ................................................................................................................................... 25
Flywheel and flywheel housing........................................................................................................... 26
Timing gear......................................................................................................................................... 28
Valve system ...................................................................................................................................... 32
Valve, valve guide .............................................................................................................................. 34
Rocker arm shaft, push rod and tappet .............................................................................................. 35
2 95E-5 Series
General structure 1

1. Crankshaft pulley 11. Oil ring 21. Valve guide
2. Front oil seal 12. Second ring 22. Valve spring
3. Crankshaft 13. Top ring 23. Cylinder head cover
4. Crankshaft gear 14. Fan pulley 24. Rocker arm bracket
5. Connecting rod 15. Piston 25. Rocker arm spring
6. Camshaft bushing 16. Water pump 26. Cylinder head
7. Camshaft gear 17. Intake valve 27. Cylinder block
8. Front cover 18. Exhaust valve 28. Push rod
9. Connecting rod bushing 19. Thermostat 29. Flywheel housing
10. Piston pin 20. Fan 30. Flywheel
4 95E-5 Series
31. Ring gear 41. Turbocharger Specifications

32. Tappet 42. Rocker arm Type: In-line, 4-cylinder, water-
33. Main bearing 43. Air intake connector cooled, direct fuel injection,
34. Rear oil seal 44. Fuel injection injector 4-cycle diesel engine
35. Thrust bearing 45. Air intake manifold
36. Oil pan 46. Rail
37. Camshaft 47. Supply pump
38. Connecting rod cap 48. Starting motor
39. Oil filter
40. Exhaust manifold
95E-5 Series 5
Air intake and exhaust system 1

Air intake and exhaust unit 1

1. Intake manifold
2. Air connector
6 95E-5 Series
A: Air intake inlet

B: Exhaust outlet
1. Muffler
2. Exhaust connector
3. Turbocharger
4. Exhaust manifold
95E-5 Series 7
Air cleaner 1
FPG type

A: Air intake inlet
B: Exhaust outlet
1. Inlet 6. Vacuator valve

2. Outlet 7. Dust pan
3. Guide vane 8. Body
4. Primary element 9. Element
5. Safety element
Features (FPG type) Structure

q The element diameter is the same and the out- q Air containing dust is sucked into the tangential
side diameter of the body is small. from inlet (1). The dust is separated by the
The inlet is placed in the direction of connec- centrifugal separation effect of guide vane (3).
tion, so no guide vane is used; a simple spiral More than 99.9% of the dust is then removed
guide vane can give ample centrifugal force. by primary element (4), and the clean air then
q The dust pan has no guide vane and its struc- passes through safety element (5) and outlet
ture is simple. (2), and is sent to the engine.
q The dust and water separated by guide vane
(3) circulates around the inside wall of body
(8), flies into vacuator valve (6), and is auto-
matically discharged.
8 95E-5 Series
Turbocharger 1
Type: TD04L
10 95E-5 Series
A: Air intake inlet

B: Air intake outlet
C: Exhaust inlet
D: Exhaust outlet
E: Oil inlet
F: Oil outlet
1. Actuator, waste gate valve

2. Blower housing
3. Bolt, flange
4. Thrust sleeve
5. Insert
6. Snap ring
7. O-ring
8. O-ring
9. Oil deflector
10. Thrust bearing
11. Thrust ring
12. Center housing
13. Coupling assembly
14. Turbine back plate
15. Piston ring
16. Turbine impeller
17. Turbine housing
18. Bearing
19. Snap ring
20. Piston ring
21. Blower impeller
22. Locknut
23. Hose
Unit: mm
No. Item Criteria Remedy
Standard Repair limit
24 End play of rotor
0.010 0.076 0.103 Repair or replace
25 Radial play of rotor 0.394 0.602 0.720
Specifications
Type: TD04L
Exhaust temperature: Max. 700C (inlet)
Direction of rotation: Clockwise (as seen from blower)
95E-5 Series 11
Outline of waste gate valve
q This maintains a suitable supercharging pres- q Pressure (A) near the outlet port of the com-
sure (set supercharging pressure) in order to pressor passes through (B) and actuates actu-
prevent any excessive load on the engine by ator (2). Waste gate valve (1) opens, and part
suppressing any supercharging above the nec- of the exhaust gas bypasses the turbine, so
essary level from the compressor. the output of the turbine drops and the set
q In order to do this, waste gate valve (1) is supercharging pressure is maintained.
installed in the exhaust circuit before the tur-
bine. When supercharged pressure (A) near
the compressor outlet port becomes high, if it
exceeds the set pressure of the actuator
(swing valve control (2)), waste gate valve
(swing valve) (1) opens.
q Point (c) where engine speed (a) and super-

charging pressure (b) intersect is the point
where the waste gate valves start to open.
12 95E-5 Series
Muffler 1
A: Exhaust gas inlet (From turbocharger)

B: Exhaust gas outlet
C: Water drain
95E-5 Series 13
Engine unit 1
Cylinder head 1

a *1: The Nos. in the illustration are the tightening order of the bolts.
14 95E-5 Series
1. Cylinder head
2. Head cover
3. Oil filler cap
4. Valve guide
5. Bracket
6. Injector for common rail
7. Fuel scatter prevention cover
Unit: mm
No. Item Criteria Remedy
Distortion of cylinder head Standard Repair limit Repair by grinding or
8
mounting surface 0 0.05 0 0.30 replace
9 Protrusion of nozzle 4.62 0.28 4.3 4.9 Replace nozzle gasket
Order Target Nm {kgm} Range Nm {kgm}
Tightening torque of cylinder 1st step 68.6 {7} 58.8 78.5 {6 8}

head mounting bolt (Coat 103 113 Tighten bolts in order
2nd step 108 {11}
10 bolt threads and washers {10.5 11.5} of Nos. shown in
with molybdenum disulphide Tightening bolt for plastic region rota- illustration.
(LM-P)) tion angle
3rd step
Retighten 90 90 (+30/0)
Tightening torque of nozzle Target Nm {kgm} Range Nm {kgm}
11
holder mounting bolt 28.5 {2.9} 27 30 {2.8 3.1}
Retighten
Tightening torque of head
12 8.8 {0.9} 7.8 9.8 {0.8 1.0}
cover mounting bolt
Specifications
Cylinder head
q Direct fuel injection type
q Unitized type
q 2 valves (1 cylinder)
q Fuel injection injector: Assembled outside head cover
Mount: Dry type (without sleeve)
Head cover
q Float mount type
95E-5 Series 15
Cylinder block 1

1. Main bearing cap
2. Main bearing cap bolt
3. Camshaft bushing (No. 1 journal)
4. Cylinder block
7. Oil pump drive shaft bushing
8. Oil pump driven shaft
16 95E-5 Series
Specifications
Cylinder block
q Crankshaft section: 5 bearings
q Camshaft section: 3 bearings
Cylinder
q Linerless
q Inside surface finishing: Honing
95E-5 Series 17
(Cam journal No.2 and No.3 : Without bushing)
Unit: mm
No. Check item Criteria Remedy
Distortion of cylinder head Standard Repair limit Replace by
1
mounting surface 0 0.08 0.15 grinding
Standard Tolerance
Inside diameter of main
+0.019
bearing hole 74
+0.000 Repair or
2 Roundness of main bearing replace
Repair limit: 0.005
hole cylinder block
Straightness of main bear-
Repair limit: 0.010
ing holes
Standard size Tolerance Repair limit
STD 70.00 70.20
Inside diameter of main 0.25 US 69.75 69.95 Replace main
3 +0.103
bearing 0.50 US 69.50 69.70 bearing
+0.058
0.75 US 69.25 69.45
1.00 US 69.00 69.20
Standard Tolerance Repair or
Inside diameter of cam
4 +0.030 replace
bushing hole 53.5
+0.000 cylinder block
Journal Standard Tolerance Repair limit
Inside diameter of cam
+0.030 Replace
bushing No. 1 50.5 50.60
5 0.040
Inside diameter of cylinder No. 2 0.031 Press fit
50.5 50.60
block No. 3 0.050 bushing
Tightening torque of main Order Target Nm {kgm} Range Nm {kgm}
bearing cap mounting bolts 1st step 113 {11.5} 108 118 {11 12}
6 Retighten
(Coat bolt threads and 2nd step 0 {0} Loosen completely
washers with engine oil) 3rd step 132 {13.5} 127 137 {13 14}
a US: Under Size
18 95E-5 Series
Cylinder 1
Unit: mm
STD 95 95.15
Inside diameter +0.022 Correct with
0.25 OS 95.25 95.40
+0.000 oversize, or
0.50 OS 95.50 95.65 install cylinder
Roundness of inside liner, or replace
Repair limit: 0.020
diameter cylinder block
Cylindricity of inside
Repair limit: 0.020
diameter
Measure inside diameter at position 40, 100, and 160 from top sur-
1 face of cylinder block. Use largest value to determine overhaul
size.
(When
1) If cylinder bore is less than 95.15: Select 0.25 oversize piston
carrying out
and machine cylinder bore in cylinder block to 95.25 +0.022
+0 . overhaul) Rank
2) If cylinder bore is between 95.16 and 95.40: Select 0.50 over- cylinder bore at
Procedure for overhaul size
size piston and machine cylinder bore in cylinder block to top face of
+0.022
95.50 +0 . cylinder block
and correct
3) If cylinder bore is more than 95.40: Carry out stepped machin-
mark (S or L)
ing of cylinder block and insert cylinder liner. For details of the
method for machining the cylinder block and selecting the cylin-
der liner, see REPAIR AND REPLACEMENT OF PARTS.
a OS: Over Size
95E-5 Series 19
Main moving parts 1
a: Offset
1. Crankshaft 10. Top ring

2. Crankshaft gear (No. of teeth: 24) 11. Second ring
3. Main bearing 12. Oil ring
4. Connecting rod bearing 13. Thrust bearing
5. Connecting rod 14. Connecting rod cap
6. Cylinder block 15. Connecting rod cap bolt
7. Piston 16. Main cap
8. Connecting rod bushing 17. Main cap bolt
9. Piston pin 18. Cam bushing
20 95E-5 Series
Specifications Piston ring

Crankshaft
q Closed die forging
Piston
q Direct fuel injection type 2-stage combustion
chamber
q Center of piston hole offset 1.0 mm (to reduce
vibration)
Top ring (1): Both faces keystone

Second ring (2):Flat tapered face, under cut,
Parkerizing treatment
Oil ring (3): Ring with coil expander
95E-5 Series 21
Crankshaft 1
Unit: mm
Standard Repair limit Repair by
using over size
1 End play
0.131 0.351 0.40 thrust bearing
or replace
STD 70.00 69.86
0.25 US 69.75 69.61 Repair by
Outside diameter of main
journal +0.015 using under
0.50 US 69.50 69.36
+0.000 size bearing or
2 0.75 US 69.25 69.11 replace
1.00 US 69.00 68.86
Roundness of main journal Repair limit: 0.020
Standard clearance Clearance limit Replace main
Clearance of main journal
0.043 0.103 0.25 bearing
STD 57.00 56.91
Outside diameter of 0.25 US 56.75 56.66 Repair by
crankpin journal +0.015
0.50 US 56.50 56.41 using under
+0.000
0.75 US 56.25 56.16 size bearing or
3 1.00 US 56.00 55.91 replace
Roundness of crankpin
Repair limit: 0.020
journal
Standard clearance Clearance limit Replace
Clearance of crankpin
connecting rod
journal 0.029 0.089 0.22 bearing
Repair by
using under
4 Bend of crankshaft Repair limit: 0.09 (Total indicated runout)
size bearing or
replace
a US: Under Size
22 95E-5 Series
Camshaft 1
(Bushing installed to journal No. 2 and 3)
Unit: mm
Standard size Repair limit Replace thrust
1 End play
0.150 0.350 0.5 plate
Standard Tolerance Standard Clearance

Journal
size Shaft Hole clearance limit
Clearance between Replace
2 No.1
camshaft and bushing 0.080 +0.030 0.040 bushing
No.2 50.5 0.25
0.110 0.040 0.140
No.3
3 Curvature of camshaft Repair limit: 0.03 (Total deflection of indicator)
Replace
4 Height of camshaft Intake 42.69 42.2
0.10
Exhaust 43.04 42.5
When testing (Crankshaft angle
Valve when valve has gone down
Crankshaft angle 1 mm)
position
Standard Tolerance Check for
Intake curvature or
Before TDC 9 Before TDC 8 wear of valve,
open
5 Valve timing camshaft, push
Intake rod.
After BDC 20 After BDC 4
closed Correct or
3
Exhaust replace
Before BDC 52 Before BDC 37
open
Exhaust
After TDC 13 After TDC 12
closed
a TDC: Top Dead Center

BDC: Bottom Dead Center
95E-5 Series 23
Piston, piston ring and piston pin 1

Standard size Repair limit Replace
STD 94.875 94.86 piston (only S
Outside diameter of piston
1 size supplied
(at right angle to boss) 0.25 OS 95.125 95.11 as replace-
0.50 OS 95.375 95.36 ment part)
Measuring
No. Standard clearance Clearance limit
2 point
2 Top ring 0.28 0.38 2.0 Replace
3 Piston ring gap
Second piston ring
3 0.40 0.50 2.0
4 ring
4 Oil ring 0.20 0.40 1.5
Measuring Standard Tolerance Standard Clear-
No.
point size Ring Piston clearance ance limit
5
0.06 *1 Judge using groove wear
5 Top ring 2.5 Replace
Clearance between piston 0.08 gauge
6 piston ring or
ring groove and piston ring Second 0.01 +0.05 0.04
6 2 0.20 piston
7 ring 0.03 +0.03 0.08
0.01 +0.04 0.03
7 Oil ring 3 0.15
0.03 +0.02 0.07
size clearance limit Replace
Clearance between piston Shaft Hole
8 piston or
and piston pin 0.000 +0.010 0.004
30 0.05 piston pin
0.006 +0.004 0.016
a *1: Part No. (wear gauge): 795-901-1130

a OS: Over Size
24 95E-5 Series
Connecting rod 1
Unit: mm
Standard Tolerance Standard Clearance Replace bush-
Clearance between con- size Shaft Hole clearance limit ing (semi-
necting rod bushing and finished part
1
piston pin (carry out 0.000 +0.033 0.020 supplied as
reaming after press fitting) 30 0.10 replacement
0.006 +0.020 0.039
part)
Inside diameter of Standard Tolerance
Replace
2 connecting rod bushing +0.025
33 connecting rod
hole +0.000
STD 57.00 57.20
0.25 US 56.75 56.95 Replace
Inside diameter of
3 +0.095 connecting rod
connecting rod bearing 0.50 US 56.50 56.70
+0.045 bearing
0.75 US 56.25 56.45
1.00 US 56.00 56.20
Inside diameter of Standard Tolerance
4 connecting rod bearing +0.025
hole 61
+0.000
Standard Repair limit Replace
Bend (a) Max. 0.20 0.25 connecting rod
Bend and twist of
5 Twist (b) Max. 0.30 0.35
connecting rod
Dimension (c) 167
Dimension (d) 167
Order Target Nm {kgm} Range Nm {kgm}
Tightening torque of con- 37 41
necting rod cap mounting 1st step 39 {4}
6 {3.8 4.2} Retighten
bolts (Coat bolt threads and
washers with engine oil) 2nd step Retighten with 90 90 (+30/0)
Tightening bolt for plastic region rotation angle
a US: Under Size
95E-5 Series 25
Flywheel and flywheel housing 1

Without rear PTO type

a 12: The Nos. in the illustration are the tightening order of the bolts.
26 95E-5 Series
1. Starting motor
2. Flywheel housing
3. Crankshaft
4. Rear oil seal (Wet type: Double lip)
5. Flywheel
6. Ring gear (No. of teeth: 127)

Face runout of flywheel
7 Repair limit: 0.30
housing Repair by
Radial runout of flywheel reassembling
8 Repair limit: 0.30
housing
Tightening torque of Target Nm {kgm} Range Nm {kgm}
9 flywheel housing mounting Retighten
bolts 66.2 {6.75} 58.8 73.5 {6.0 7.5}
10 Radial runout of flywheel Repair limit: 0.35 Repair by

11 Face runout of flywheel Repair limit: 0.30 reassembling
Tightening torque of Order Target Nm {kgm} Range Nm {kgm}
flywheel mounting bolts 1st step 88.3 {9.0} 58.8 118 {6.0 12.0} Retighten
12
(Coat bolt threads and
washers with engine oil) 2nd step 191 {19.5} 186 196 {19 20}
95E-5 Series 27
Timing gear 1
Without front PTO type (Spur gear)
A, B: Match marks for timing gears
1. Camshaft gear (No. of teeth: 52)

2. Idler gear (No. of teeth: 52)
3. Supply pump drive gear (No. of teeth: 31)
4. Crankshaft gear (No. of teeth: 26)
5. Oil pump drive gear (No. of teeth: 22)
6. Shaft
7. Bushing
8. Thrust plate
9. Front seal
28 95E-5 Series
Specification
Front oil seal
q Single lip with dust seal
95E-5 Series 29
(Without front PTO)
Unit: mm
Measuring
Gears Standard Repair limit
point
Crankshaft gear and idler
A 0.07 0.33
gear
Replace
Idler gear and camshaft
1 Backlash of each gear B 0.09 0.36 bushing or
gear
0.4 gear
Idler gear and supply
C 0.06 0.33
pump gear
Camshaft gear and oil
a 0.07 0.33
pump gear
Standard Tolerance Standard Clearance Replace
size Shaft Hole clearance limit bushing (semi-
Clearance between idler finished part
2
gear bushing and shaft 0.000 +0.083 0.018 supplied as
45 0.10 replacement
0.016 +0.018 0.099
part) or gear
Standard Repair limit Replace idler
3 End play of idler gear shaft, thrust
0.03 0.09 0.20 plate or gear
30 95E-5 Series
Valve system 1
1. Cam gear (No. of teeth: 52) 10. Valve cotter

2. Thrust plate 11. Valve stem cap
3. Camshaft 12. Spring seat
4. Tappet 13. Rocker arm spring
5. Push rod 14. Rocker arm bracket
6. Exhaust valve 15. Rocker arm shaft
7. Intake valve 16. Adjustment screw
8. Valve spring 17. Locknut
9. Valve seal 18. Rocker arm
32 95E-5 Series
Specifications
Valve lift
q Intake valve: 9.6 mm
q Exhaust valve: 10.6 mm
95E-5 Series 33
Valve, valve guide 1
Unit: mm
Tolerance Repair limit
Repair valve or
1 Sinking of valve Air intake 1.0 0.18
1.00 valve seat
Exhaust 0.9 0.18
2 Thickness of valve head 15 1.0 1.00 Replace
Standard Tolerance Repair limit Correct valve
3 Valve seat angle Judge contact surface or valve seat,
45 15
condition with vacuum test or replace
size Shaft Hole clearance limit
Replace either
Clearance between valve 0.035 +0.015 0.035
4 Air intake 8 0.20 valve or valve
guide and valve stem 0.050 +0.000 0.065 guide or both
0.050 +0.015 0.050
Exhaust 8 0.20
0.065 +0.000 0.080
Part No.
Standard size Repair limit
(distinguishing feature)
6204-41-4410
Free length of valve spring 49.2 48.5
(Peach-color)
6204-41-4431
56.0 55.0
(Red)
Standard Allowable
Part No. Installed
5 Installed load installed load Replace
(distinguishing feature) length
N {kg} N {kg}
Installed load of valve 6204-41-4410 181 8.8 162
spring 40.5
(Peach-color) {18.5 0.9} {16.5}
6204-41-4431 153 14.7 127
40.5
(Red) {15.6 1.5} {13.0}
Out-of-square of valve
Repair limit: 18.5
spring
Driving-in height of valve Standard size Tolerance
6 Correct
guide 14.5 0.2
34 95E-5 Series
Rocker arm shaft, push rod and tappet 1
Unit: mm
Standard Tolerance
Outside diameter of rocker Replace rocker
arm shaft 0.000 arm shaft
19
0.020
Inside diameter of rocker +0.030 Replace rocker
1 19
arm shaft hole +0.010 arm
Clearance between rocker Standard clearance Clearance limit Replace rocker
arm and rocker arm shaft 0.010 0.050 0.12 arm or rocker
Bend of rocker arm shaft Repair limit: 0.20 (Total indicated runout) arm shaft
Replace push
2 Bend of push rod Repair limit: 0.30 (Total indicated runout)
rod
Tightening torque of Target Nm {kgm} Range Nm {kgm}
3 Retighten
rocker arm nut 44 {4.5} 39 49 {4 5}
Valve Standard Tolerance
Valve clearance
4 Air intake 0.35 0.02 Adjust
(at warm and cold)
Exhaust 0.50 0.02
Standard Tolerance
Replace
Outside diameter of tappet 0.015
16 tappet
0.030
5 Inside diameter of tappet +0.018 Replace

16
hole 0.000 cylinder block
Standard clearance Clearance limit Replace
Clearance between tappet
tappet or
and tappet hole 0.015 0.048 0.12 cylinder block
95E-5 Series 35
SEN02126-00
2006 KOMATSU
All Rights Reserved
36
SEN02127-00
ENGINE 1SHOP MANUAL
95E-5 Series
10 Structure, function and

maintenance standard 1
Structure, function and maintenance
standard, Part 2
Lubrication system .......................................................................................................................................... 3
Lubrication system diagram ................................................................................................................. 3
Oil pump............................................................................................................................................... 4
Regulator valve .................................................................................................................................... 6
Oil filter ................................................................................................................................................. 7
Fuel system..................................................................................................................................................... 9
Fuel system diagram............................................................................................................................ 9
Supply pump ...................................................................................................................................... 10
Fuel injection nozzle........................................................................................................................... 12
Fuel filter ............................................................................................................................................ 13
Common rail....................................................................................................................................... 14
95E-5 Series 1
Various sensor.................................................................................................................................... 16
Cooling system.............................................................................................................................................. 18
Cooling system diagram..................................................................................................................... 18
Water pump ........................................................................................................................................ 19
Cooling fan drive and thermostat ....................................................................................................... 22
Electrical equipment...................................................................................................................................... 26
Starting and charging system electrical circuit diagram ..................................................................... 26
Alternator............................................................................................................................................ 27
Starting motor ..................................................................................................................................... 29
Starting aid ......................................................................................................................................... 30
Engine controller ................................................................................................................................ 31
2 95E-5 Series
Lubrication system 1
Lubrication system diagram 1
1. Oil strainer
2. Oil pump
3. Regulator valve
4. Oil filter
5. Safety valve
6. Crankshaft
7. Camshaft
8. Piston
9. Air intake valve and exhaust valve
10. Rocker arm
11. Timing gear
95E-5 Series 3
Oil pump 1
1. Bushing Specifications
2. Drive gear (No. of teeth: 7) Oil pump
3. Pump cover q Type: Gear pump
4. Oil pump drive gear (No. of teeth: 22) q Pump speed: Engine speed 1.182
5. Drive shaft
6. Driven shaft Regulator valve
7. Driven gear (No. of teeth: 7) q Set pressure: 588 49 kPa {6.0 0.5 kg/cm2}
8. Regulator valve
9. Valve spring
4 95E-5 Series
Unit: mm
Tolerance Standard Clearance
Standard
clearance limit
Axial clearance of pump size Gear width Body width
1 (End play) (End play)
gear
0.000 0.070 0.030
21 0.10
0.016 +0.030 0.086
Replace gear
Radial clearance of pump size Gear OD Body OD clearance limit
2
gear +0.115 +0.245 0.045
38 0.13
+0.065 +0.205 0.090
Interference between pump size Shaft Hole clearance limit
3 Replace
drive gear and drive shaft 0.024 0.067 0.025
13
0.042 0.085 0.061
Clearance between drive 0.024 +0.018 0.024 Replace
4 13
shaft and cover 0.042 +0.000 0.060 bushing
Interference between pump 0.024 0.065 0.025
5 13 Replace
gear and drive shaft 0.042 0.086 0.061
Clearance between drive 0.024 +0.048 0.028 Replace
6 13
shaft and bushing 0.042 +0.004 0.09 bushing
Interference between
0.064 +0.018 0.028 Replace
7 driven shaft and cylinder 16
+0.046 +0.000 0.064 cylinder block
block
Clearance between driven 0.110 0.065 0.024 Replace shaft
8 13
shaft and gear 0.125 0.086 0.060 or gear
Inside diameter of cylinder
0.087 +0.018 0.042 Replace
9 block for drive shaft 16
+0.060 +0.000 0.087 cylinder block
bushing
a OD: Outer Diameter
95E-5 Series 5
Regulator valve 1
Unit: mm
Tolerance Standard
Standard size
Clearance between valve Shaft Hole clearance
1 Replace
and body 0.050 +0.020
11 0.030 0.097
0.077 0.020
Free length
Standard size: 33.1
Installed load
2 Regulator valve spring Replace
Standard load Load limit
Installed length
N {kg} N {kg}
27.8 19.7 {2.0} 55.9 {5.7}
Regulator valve set Repair or
3 Standard: 0.6 0.05 MPa {6.0 0.5 kg/cm2}
pressure replace spring
6 95E-5 Series
Oil filter 1
A: Oil inlet
B: Oil outlet
1. Relief valve
2. Cartridge
3. Bracket
Specifications
Relief valve
q Cracking pressure: 100 20 kPa {1 0.2 kg/cm2}
95E-5 Series 7
Oil filter mounting
1. Oil cooler
2. Cartridge
3. Bracket
8 95E-5 Series
Fuel system 1
Fuel system diagram 1
1. Fuel tank
2. Priming pump
3. Pre-filter with water separator
4. Main filter
5. Feed pump
6. IMV (Inlet Metering Valve)
7. Overflow valve
8. Rail
9. Injector
10. Safety valve
11. High pressure pump
95E-5 Series 9
Supply pump 1

1. High pressure value Specifications
2. Inlet valve Supply pump
3. Piston q Type: Bosch type CP1H-OHW
4. Cam q Lubrication method: Lubrication with fuel
5. MPROP (Fuel quantity adjustment solenoid valve)
6. Gear pump Governor
Type: Electronic control
10 95E-5 Series
Supply pump mounting
A: Fuel inlet (From fuel filter) D: To spill

B: From supply pump to rail E: To fuel tank
C: From rail to injector
1. Drive shaft 5. High pressure pipe 9. Fuel injection pipe (No. 3)

2. Supply pump drive gear (Between pump and rail) 10. Fuel injection pipe (No. 4)
(No. of teeth 31) 6. Fuel filter 11. Spill tube
3. Pump holder 7. Fuel injection pipe (No. 1) 12. Rail
4. Supply pump 8. Fuel injection pipe (No. 2) 13. Injector
a When removing high-pressure pipe (5) and

fuel injection pipes (7), (8), (9) and (10), apply
a counter spanner to the connector on the sup-
ply pump (4) and injector (13) side.
95E-5 Series 11
Fuel injection nozzle 1

For direct fuel injection type
A: Fuel inlet (from supply pump) Specifications

B: Fuel return (to fuel tank) q Type: Bosch CRI2.0 injector
q Injection pressure:
1. Backup ring 25.4 108 MPa {250 1,100 kg/cm2}
2. 2-way valve
3. Armature
4. Lock sleeve
5. Valve spring
6. Magnet
7. Inlet connector
8. Valve
9. Injector body
10. Nozzle
12 95E-5 Series
Fuel filter 1
A: Fuel inlet
B: Fuel outlet
1. Plug
2. Filter bracket
3. Cartridge
Specifications
q Filtration area: 0.2 m2
95E-5 Series 13
Common rail 1
A: From supply pump Structure

B: To No. 1 injector q Common rail (1) distributes the high-pressure
C: To No. 2 injector fuel from the high-pressure pump to the injectors
D: To No. 3 injector of the cylinders.
E: To No. 4 injector q Common rail (1) is equipped with fuel pressure
sensor (3), HP connection (4), and pressure lim-
F: Fuel outlet when limiter is open
iter (2).
q The fuel injection pipes are connected to HP con-
1. Common rail nection (4) to send the high-pressure fuel to the
2. Pressure limiter injectors.
3. Fuel pressure sensor q The piping of the pressure limiter (2) is returned
4. HP connection to the fuel tank.
14 95E-5 Series
Various sensor 1
16 95E-5 Series
1. Camshaft speed sensor

2. Crankshaft speed sensor
3. Coolant temperature sensor
4. Boost pressure/temperature sensor
5. Oil pressure switch
6. Common rail pressure sensor
7. Atmospheric pressure sensor
95E-5 Series 17
Cooling system 1
Cooling system diagram 1
1. Radiator
2. Thermostat
3. Water temperature gauge
4. Water pump
5. Water manifold
6. Cylinder head
7. Piston
8. Cylinder block
18 95E-5 Series
Water pump 1
(With separate type water seal, bearing, integrated shaft)

A: Water inlet (from radiator)
B: Water inlet (from thermostat)
C: Water outlet (to engine)
D: Water outlet (to radiator)
1. Pump cover
2. Impeller
3. Water seal
4. Pump body
5. Boss
6. Drive shaft
Specification
q Type: Centrifugal type (V-belt drive)
95E-5 Series 19
Unit: mm
1 Clearance of impeller body Standard clearance: 0.3 2.0
Tolerance Standard
Standard size
Interference between shaft Shaft Hole interference
2
and fan pulley boss 0.000 0.066
18 0.053 0.082
0.013 0.082
Interference between shaft 0.000 0.025
3 42 0.012 0.046 Replace
and body 0.013 0.046
Interference between shaft 0.000 0.035
4 12 0.022 0.062
and impeller 0.013 0.062
5 Curvature of shaft Repair limit: Runout at face (B): 0.1
Wear of seal ring of water
6 Repair limit: Dimension (A): 0
seal
20 95E-5 Series
Cooling fan drive and thermostat1

A: Direction of wind 1. Fan
B: To radiator (coolant) 2. Fan belt
C: From engine (coolant) 3. Water pump
a, b, c: Outside diameter of pulley 4. Fan spacer
d: Heater pickup port 5. Fan pulley
e: Thermo sensor 6. Crankshaft pulley
f: Water temperature gauge pickup port 7. Crankshaft
8. Thermostat case cover
9. Thermostat
10. Thermostat case
11. Alternator
22 95E-5 Series
Cooling fan drive
Outside diameter of pulley

Unit: mm
Fan Alternator Crankshaft pulley
Engine Machine model
a b c
PC138US-8,
SAA4D95LE-5 189 76.1 170
PC138USLC-8
95E-5 Series 23
Thermostat (with jiggle valve)
1. Piston a Jiggle valve (12) allows air to flow but stops

2. Case water from flowing to the top of thermostat. It
3. Pellet allows the engine water temperature to rise in a
4. Seat short time.
5. Valve
6. Case
7. Spring
8. Bypass spring
9. Bypass valve
10. Bypass seat
11. E-ring
12. Jiggle valve
24 95E-5 Series
Unit: mm
Cracking temperature: 76 2C Fully open: Shall open fully when
Fully open temperature: 95C immersed in hot water bath at
temperature between 95C and
1 Thermostat 77C for 4 5 minutes Replace
Fully open lift: Min. 8
(when immersed in hot water
bath at 95C for 4 5 minutes)
95E-5 Series 25
Electrical equipment 1
Starting and charging system electrical circuit diagram 1
1. Battery
2. Starting motor
3. Alternator
4. Starting switch
5. Relay
6. Electrical intake air heater
26 95E-5 Series
Alternator 1
Alternator with built-in regulator (Open type, 35A)

1. Alternator (body)
2. Alternator pulley
3. Terminal B
4. Internal connection diagram
4A. Alternator assembly
4B. IC regulator
4C. Terminal L load
4D. Starting switch
4E. Battery
Pulley
Machine Outside
Engine Type Specifications Number of Weight (kg)
model diameter
stage
(mm)
PC138US-8, Open type manufactured
SAA4D95LE-5 24 V, 35 A 1 76.1 4.7
PC138USLC-8 by NIHON DENSO
95E-5 Series 27
Alternator mounting

a: Outside diameter of alternator pulley: 76.1 mm
b: Outside diameter of crankshaft pulley: 170 mm
1. Alternator
2. Nut (2 pieces)
3. Adjustment rod
4. V-belt
28 95E-5 Series
Starting motor 1
For 4.5 kW

1. Pinion gear 8. Internal connection diagram
2. Magnetic switch 8A. Relay
3. Starting motor assembly 8B. Starting switch
4. Jump start prohibition warning plate 8C. Battery
5. Jump start prevention cover 8D. 30 (terminal B)
6. 50 (terminal C) 8E. 50 (terminal C)
7. 30 (terminal B)
Number of
Engine Machine model Type Specifications Weight (kg)
pinion teeth
PC138US-8, Drip proof, oil proof type manu-
SAA4D95LE-5 24 V, 4.5 kW 11 8.5
PC138USLC-8 factured by NIHON DENSO
95E-5 Series 29
Starting aid 1
Electric heater

1. Heater coil Specification
2. Housing Type of heater: Electrical intake air heater
3. Internal connection diagram q Rated voltage: 22V (DC)
q Load current: 110A
30 95E-5 Series
Engine controller 1
1. Controller body
2. Engine wiring harness connector
3. Machine wiring harness connector
4. Electric power supply
Specifications
Dimensions
Type Weight Voltage
A B C D
CM2150 277 218 61 60 1,950kg 12V, 24V
95E-5 Series 31
SEN02127-00
2006 KOMATSU
All Rights Reserved
32
SEN02129-00
ENGINE 1SHOP MANUAL
95E-5 Series
20 Standard value table 1

Standard service value table
Standard service value table ........................................................................................................................... 2
Standard service value table for testing, adjusting, and troubleshooting ............................................. 2
Running-in standard and performance test standard ........................................................................... 3
95E-5 Series 1
SEN02129-00 20 Standard value table
Standard service value table 1

Standard service value table for testing, adjusting, and troubleshooting 1
Engine SAA4D95LE-5
Machine model PC138US-8, PC138USLC-8
Performance Category
Standard value Service limit

Item Measurement conditions Unit
for new machine value
Max. speed at no load rpm 2,300 60 2,300 60

Speed
Min. speed at no load rpm 1,100 50 1,100 50
Necessary speed for At 0C (without starting aid) rpm Min. 150 Min. 150
starting At 20C (with starting aid) rpm Min. 100 Min. 100
kPa Max. 3.73 7.47
Air intake resistance Whole speed range
{mmH2O} {Max. 380} {762}
kPa
Air boost pressure At rated output
{mmHg}
Exhaust pressure kPa
At rated output
Air intake and exhaust system
(Turbine inlet press.) {mmHg}

Exhaust temperature
Whole speed range (20C) C Max. 650 700
(Turbine inlet temp.)
% Max. 30 30
At sudden acceleration (Low High) (Bosch (only engine (only engine
index) side) side)
%
Exhaust gas color At rated output (Bosch Max. 15 35
index)
%
At high idle (Bosch Max. 10 20
index)
Valve clearance (When Intake valve mm 0.35

engine is hot or cold) Exhaust valve mm 0.50
Compression pressure Engine oil temperature: 40 60C MPa Min. 2.9 2.0
(SAE30 or SAE 15W-40) Engine speed: 320 360 rpm {kg/cm2} {Min. 30} {20}
Body
Blow-by pressure At rated output kPa Max. 0.59 0.98

(SAE30 or SAE 15W-40) Engine coolant temperature: Min. 70C {mmH2O} {Max. 60} {100}
At rated flywheel horsepower MPa 0.34 0.61 0.25
SAE30 or SAE15W-40 oil {kg/cm2} {3.5 6.0} {2.5}
MPa 0.29 0.49 0.21
Lubrication system
Oil pressure SAE 10W oil

{kg/cm2} {3.0 5.0} {2.1}
(Oil temperature: Min.
80C) At low idling MPa Min. 0.18 0.15
SAE30 or SAE15W-40 oil {kg/cm2} {Min. 1.8} {1.5}
MPa Min. 0.15 0.13
SAE 10W oil
{kg/cm2} {Min. 1.5} {1.3}
Oil temperature Whole speed range (Oil in oil pan) C 90 110 120
Oil consumption Ratio to fuel consumption at continuous rated output % Max. 0.5 1.0
MPa
Cooling system
Function of radiator
Cracking pressure (Differential pressure)
pressure valve {kg/cm2}
Fan speed At rated speed rpm 1,980 60 1,980 60
Fan belt tension Deflection under finger pressure of 59 N {6 kg} mm 6 6 10
a This STANDARD VALUE TABLE does not give the standard value for adjusting the engine output.
Do not use the values in this table to change the setting for fuel injection pump.
2 95E-5 Series
20 Standard value table SEN02129-00
Running-in standard and performance test standard 1

Running-in standard
Engine SAA4D95LE-5
Procedure
Item
1 2 3 4 5
Running time min. 2 10 2 3 2
Speed rpm 1,100 (+50/0) 1,100 1,450 1,900 2,200
Dynamometer load N{kg} 0{0} 142{14.5} 235{24} 335{34.2} 437{44.5}
Output kW{HP} 0{0} 11.8{15.8} 25.7{34.5} 47.8{64.0} 72.1{96.6}
a This table shows the values when the fan is not installed.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Performance test standard
Engine SAA4D95LE-5
Max. speed at Min. speed at
Test item Rated output Max. torque
no load no load
Specification value 72.1 kW/2,200 rpm (Gross) 358 Nm/1,500 rpm (Gross)
2,300 60 rpm 1,100 50 rpm
(Gross value) {96.6 HP/2,200 rpm} (Gross) {36.5 kgm/1,500 rpm} (Gross)
Speed rpm 2,200 5 1,500 100
N 415 459 476 525
Dynamometer load
{kg} {42.3 46.8} {48.5 53.5}
kW 68.5 75.7
Output (Gross value)
{HP} {91.8 101.5}
Nm 340 376
Torque (Gross value)
{kgm} {34.7 38.3}
Fuel consumption sec/200cc
Coolant temperature C 80 95 80 95 80 95 80 95
Lubricating oil
C 90 110 90 110 90 110 80 110
temperature
Lubricating oil MPa 0.34 0.61 0.34 0.61 0.34 0.61 Min. 0.18
pressure {kg/cm2} {3.5 6.0} {3.5 6.0} {3.5 6.0} {Min. 1.8}
Exhaust temperature C Max. 640 Max. 670
a The table gives the values under the standard condition (Atmospheric temperature: 25C, Atmospheric
pressure: 99.9 kPa {750 mmHg}).
a Since the dynamometer loads, output, and torque in the table are measured with the fan removed, they
are different from the specification values.
a The values in the table are the standard values for machines with the muffler and air cleaner installed,
alternator under no load, and air compressor open (if installed).
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
a For fuel, use ASTM D975 No. 1 or No. 2.
a For lubricant, use SAE15W-40 or SAE30 oil.
95E-5 Series 3
SEN02129-00
2006 KOMATSU
All Rights Reserved
4
SEN02182-00
ENGINE 1SHOP MANUAL
95E-5 Series
30 Testing and adjusting 1
Testing and adjusting

Testing and adjusting tools list ........................................................................................................................ 3
Measuring intake air pressure......................................................................................................................... 4
Testing exhaust temperature........................................................................................................................... 5
Adjusting valve clearance ............................................................................................................................... 6
Testing compression pressure ........................................................................................................................ 8
Testing blow-by pressure .............................................................................................................................. 10
Testing oil pressure ........................................................................................................................................11
Handling fuel system parts............................................................................................................................ 12
Releasing residual pressure in fuel system .................................................................................................. 12
Testing fuel pressure..................................................................................................................................... 13
Reduced cylinder mode operation ................................................................................................................ 14
No-injection cranking .................................................................................................................................... 14
Testing leakage from pressure limiter and return rate from injector .............................................................. 15
Bleeding air from fuel circuit.......................................................................................................................... 18
Testing fuel system for leakage..................................................................................................................... 20
Testing and adjusting alternator belt tension................................................................................................. 21
95E-5 Series 1
SEN02182-00 30 Testing and adjusting
Handling controller voltage circuit ................................................................................................................. 22
2 95E-5 Series
Testing and adjusting tools list 1
Sym-
Testing and adjusting item Part No. Part name Q'ty Remarks
bol
Testing exhaust
A 799-101-1502 Digital thermometer 1 99.9 1,299C
temperature
Commercially Intake: 0.35 mm
Adjusting valve clearance B Clearance gauge 1
available Exhaust: 0.50 mm
1 795-502-1590 Compression gauge 1 0 7 MPa {0 70 kg/cm2}
Testing compression
C 795-471-1420 Adapter 1
pressure 2 For 95E-5
6271-11-3880 Gasket 1
Testing blow-by pressure D 799-201-1504 Blow-by checker 1 0 5 kPa {0 500 mmH2O}
Pressure gauge: 2.5, 6, 40, 60 MPa
799-101-5002 Hydraulic tester 1
1 {25, 60, 400, 600 kg/cm2}
Testing oil pressure E
790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
2 799-401-2320 Hydraulic tester 1 Pressure gauge: 1 MPa {10 kg/cm2}
Pressure gauge: 2.5, 6, 40, 60 MPa
799-101-5002 Hydraulic tester 1
1 {25, 60, 400, 600 kg/cm2}
790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
Testing fuel pressure F
2 799-201-2202 Boost gauge kit 1 Pressure gauge: 1 MPa {10 kg/cm2}
795-471-1450 Adapter 1 8 1.25 mm o R1/8
3
07005-00812 Seal washer 1
1 6151-51-8490 Spacer 1 Inside diameter: 14 mm
2 6206-71-1770 Joint 1 Inside diameter of joint: 10 mm
3 07042-20108 Plug 1 PT1/8
Commercially
4 Hose 1 15 mm x 2 3 m
Testing leakage from available
pressure limiter and return G Commercially
rate from injector 5 Hose 1 5 mm x 2 3 m
available
Commercially
6 Measuring cylinder 1
available
Commercially
7 Stopwatch 1
available
For Ne sensor, Bkup sensor (Cam
799-601-4130 T-adapter
sensor)
799-601-4190 Socket For common rail pressure sensor
799-601-4240 Socket For atmospheric pressure sensor
For boost pressure and temperature
799-601-4380 Socket
sensor
799-601-4160 T-adapter For lubricating oil pressure switch
Troubleshooting for 795-799-5530 Socket For coolant temperature sensor

controllers, H 799-601-4340 Socket For supply pump IMV, injector
sensors, and actuators 799-601-4260 T-adapter For controller (4-pole)
For controller (60-pole: for engine ter-
799-601-4220 T-adapter
minal)
For controller (60-pole: for chassis
799-601-4390 Socket
terminal)
799-601-9320 T-box
For 24-pole type
799-601-9310 Plate
799-601-4350 T-box For 60-pole type
95E-5 Series 3
Measuring intake air pressure 1
q Since there is not a pressure pickup plug,

check the value from the intake air pressure
sensor of the INSITE (bench test device) or
monitor of the applicable machine.
4 95E-5 Series
Testing exhaust temperature 1 4. Run the engine and test the exhaust tempera-
ture in the whole speed range.
a Testing tools for exhaust temperature a When testing with the engine mounted on
the machine, test on the condition
Symbol Part No. Part name described in the shop manual for the
A 799-101-1502 Digital thermometer machine.
k Remove and install the testing tools after

the exhaust manifold temperature has low-
ered.
a The test point is subject to machine models.
1. Remove the exhaust manifold cover.
2. Remove exhaust temperature pickup plug (1)

from the side face of the center of the exhaust
manifold.
5. After finishing testing, remove the testing tools

and return the removed parts.
3. Install sensor [1] of digital thermometer A and

connect it to thermometer [2].
95E-5 Series 5
Adjusting valve clearance 1 [Reference information when mounted on

machine]
a Adjusting tools for valve clearance q If plug (c) of the flywheel housing is
removed, you can check the No. 1 cylin-
Symbol Part No. Part name der top dead center mark (white paint) on
Commercially the flywheel side.
B Clearance gauge q You can install the barring tool for rotating
available
the crankshaft by removing cover (d) of
the flywheel housing.
1. Remove cylinder head covers (1). q For details, see the shop manual for the
applicable machine.
2. Rotate the crankshaft forward (clockwise seen

from the front) and set wide notch (a) (Width: a When the No. 1 cylinder is at the compres-
25 mm) of signal plate (1) at the rear of the sion top dead center, the rocker arm of the
c r a n k s h a ft p u l l e y t o e m b o s s e d l e t t e r s No. 1 cylinder can be moved by the valve
"1.4TOP" (b) of front cover (2). clearance with the hand. If the rocker arm
Reference: All of the other notches of the sig- cannot be moved, rotate the crankshaft
nal plate are 5 mm in width. one more turn.
a Rotate the crankshaft with the crankshaft
pulley bolt (3) (Width across flats: 27 mm). 3. Adjust the clearances of the valves marked
a Always rotate the crankshaft pulley bolt with q in the valve arrangement drawing
forward to prevent it from being loosened. according to the following procedure.
6 95E-5 Series
1) While fixing adjustment screw (3), loosen 4. Rotate the crankshaft forward by one turn to
locknut (4). set the No. 4 cylinder to the compression top
2) Insert clearance gauge B in the clearance dead center and adjust the valve clearances
between rocker arm (5) and valve stem marked with Q, similarly to the valves marked
upper end (6) and adjust the valve clear- with q.
ance with adjustment screw (3). Reference: You may rotate the crankshaft pul-
a With the clearance gauge inserted, ley by 180 and adjust the valve
turn the adjustment screw to a degree clearance of the cylinder which is
that you can move the clearance set to the compression top dead
gauge lightly. center at this time (Firing order: 1
a Valve clearance 2 4 3).
Intake valve: 0.35 0.02 mm
Exhaust valve: 0.50 0.02 mm 5. After finishing adjustment, return the removed
3) While fixing adjustment screw (3), tighten parts.
locknut (4). 3 Cylinder head cover mounting nut:
3 Locknut: 8.82 0.98 Nm {0.9 0.1 kgm}
39.2 49 Nm {4 5 kgm}
a After tightening the locknut, check the
valve clearance again.
95E-5 Series 7
Testing compression pressure 1
a Testing tools for compression pressure
Symbol Part No. Part name

1 795-502-1590 Compression gauge
C 795-471-1420 Adapter
2
6271-11-3880 Gasket
k When measuring the compression pres-

sure, take care not to burn yourself on the
exhaust manifold, muffler, etc. or get
caught in a rotating part.
a Measure the compression pressure after the
engine is warmed up 2. Insert adapter C2 in the injector mounting hole
(Engine oil temperature: 40 60C). and fix it with holder (7).
a Fit the gasket to the adapter end.
3 Holder mounting bolt:
1. Remove the injector of the cylinder to be mea-
sured. 27 30 Nm {2.8 3.1 kgm}
a Measuring procedure for No. 1 cylinder is a Seat the fulcrum of the holder perfectly
described below as an example. before tightening the mounting bolts.
1) Remove wiring harness connector (2)
from injector (1).
2) Remove fuel scatter prevention cover (3)
from the joint.
3) Remove clamp (4) and high-pressure pipe
(5).
4) Pull out spill hose connector (6) from
injector (1).
3. Connect compression gauge C1 to adapter

C2.
5) Remove holder (7) and injector (1).

a If injector is stuck and cannot be
removed easily, pass a wire under the
fuel inlet and pull it up to remove the
injector.
a Do not apply an external force to any
part other than the injector top termi-
nal.
8 95E-5 Series
4. Connect the INSITE (bench test device) to the 3) Connect spill hose connector (6) to injec-
engine controller and set it in the no-injection tor (1).
cranking mode. 4) Install high-pressure pipe (5).
q Instead of the above work, you may dis- 3 High-pressure pipe flare nut (Both
connect the wiring harness connectors ends):
from all the injectors so that fuel will not be 25.5 29.4 Nm {2.6 3.0 kgm}
injected at all. 5) Install fuel scatter prevention cover (3) to
k Since starting of engine is dangerous, the joint of high-pressure pipe (5).
be sure to set the injectors so that they a Install fuel scatter prevention cover
will not inject fuel before starting the (3) with the slit down (on both injector
check. side and common rail side).
6) Install clamp (4) to high-pressure pipe (5).
5. Crank the engine with the starting motor and a Install the clamp to the position from
measure the compression pressure. which it was removed. (The mounting
a Read the pressure when the gauge bolt goes through the clamp and
pointer is stabilized. enters the bolt hole of the air intake
manifold. Accordingly, if the mounting
6. After finishing measurement, remove the mea- bolt is installed normally, the clamp is
suring instruments and return the removed installed to its original position.)
parts according to the following procedure. 7) Connect wiring harness connector (2) to
1) Install O-ring (8) and gasket (9) to injector injector (1).
(1).
a Do not install O-ring (8) to groove "a".
2) Insert injector (1) in the cylinder head and

fix it with holder (7).
3 Holder mounting bolt:
27 30 Nm {2.8 3.1 kgm}
a Seat the fulcrum of the holder per-
fectly before tightening the mounting
bolts.
95E-5 Series 9
Testing blow-by pressure 1
a Testing tool for blow-by pressure

D 799-201-1504 Blow-by checker
1. Install nozzle [1] of blow-by checker D to the

end of breather hose (1).
2. Connect hose [2], and then connect it to gauge

[3].
3. Run the engine at the rated output and test the

blow-by pressure.
a When testing with the engine mounted on
described in the shop manual for the
machine.

10 95E-5 Series
Testing oil pressure 1
a Testing tools for oil pressure

799-101-5002 Hydraulic tester
1
E 790-261-1204 Digital hydraulic tester
2 799-401-2320 Hydraulic tester
1. Remove 1 oil pressure pickup plug (1) from the

left side of the cylinder block.
a Remove any one of the 3 oil pressure
pickup plugs. 4. After finishing testing, remove the testing tools
2. Connect nipple [1] of hydraulic tester E1 and

connect it to hydraulic tester E2.
3. Run the engine at the rated output and low idle

and test the oil pressure.
a When testing with the engine mounted on
described in the shop manual for the
machine.
95E-5 Series 11
Handling fuel system parts 1 Releasing residual pressure in

a Precautions for testing and maintaining fuel fuel system 1
system a Pressure is generated in the low-pressure cir-

The common rail fuel injection system (CRI) cuit and high-pressure circuit of the fuel sys-
consists of more precise parts than the con- tem while the engine is running.
ventional fuel injection pump and nozzle. If for- Low-pressure circuit:
eign matter enters this system, it can cause a Feed pump Fuel filter Supply pump
trouble. High-pressure circuit:
When testing and maintaining the fuel system, Supply pump Common rail Injector
take care more than the past. If dust, etc. a The pressure in both low-pressure circuit and
sticks to any part, wash that part thoroughly high-pressure circuit lowers to a safety level
with clean fuel. automatically 30 seconds after the engine is
a Precautions for replacing fuel filter cartridge stopped.
Be sure to use the Komatsu genuine fuel filter a Before the fuel circuit is tested and its parts are
cartridge. removed, the residual pressure in the fuel cir-
Since the common rail fuel injection system cuit must be released completely. Accordingly,
(CRI) consists of more precise parts than the observe the following.
conventional fuel injection pump and nozzle, it k Before testing the fuel system or removing
employs a high-efficiency special filter to pre- its parts, wait at least 30 seconds after stop-
vent foreign matter from entering it. ping the engine until the residual pressure
If a filter other than the genuine one is used, in the fuel circuit is released. (Do not start
the fuel system may have a trouble. Accord- the work just after stopping the engine
ingly, never use such a filter. since there is residual pressure.)
12 95E-5 Series
Testing fuel pressure 1 3. Run the engine at high idle and measure the
fuel pressure.
a Testing tools for fuel pressure a If the fuel pressure is in the following
range, it is normal.
Symbol Part No. Part name Reference: A value is negative pressure.
799-101-5002 Hydraulic tester Engine speed Fuel pressure
1
790-261-1204 Digital hydraulic tester 49 0 kPa
High idle
F 2 799-201-2202 Boost gauge kit {0.5 0 kg/cm2}
795-471-1450 Adapter
3
07005-00812 Seal washer
a Test only the fuel pressure in the low-pressure

circuit from the feed pump through the fuel fil-
ter to the supply pump.
k Since the pressure in the high-pressure cir-
cuit from the supply pump through the
common rail to the injector is very high, it
cannot be measured.
1. Remove plug (1) from the fuel filter head.

3 Plug: 7.8 9.8 Nm {0.8 1.0 kgm}
2. Install adapter F3 and nipple [1] of hydraulic

tester F1 and connect it to hydraulic tester F2.
3 Adapter F3:
7.8 9.8 Nm {0.8 1.0 kgm}
95E-5 Series 13
Reduced cylinder mode operation1 No-injection cranking 1
a Reduced cylinder mode operation means to a No-injection cranking means to crank the
run the engine with the fuel injectors of 1 or engine with the starting motor while all the
more cylinders disabled electrically to reduce injections are stopped electrically. The pur-
the number of effective cylinders. The purpose and effect of this operation are as follows.
poses and effects of this operation are as fol- q Before the engine is started after it or the
lows. engine unit has been stored for a long period,
1. This operation is used to find out a cylinder the no-injection cranking is performed to lubri-
which does not output power normally (or, cate the engine parts and protect them from
combustion in it is abnormal). seizure.
2. When a cylinder is selected for the reduced a Perform the no-injection operation with the
cylinder mode operation, if the engine speed engine mounted on the machine or connected
and output do not change from the normal to INSITE (bench test tool).
operation (all-cylinder operation), that cylinder a Before performing, see "Testing method" in the
has 1 or more defects. shop manual for the machine or INSITE
The possible defects are as follows. (bench test tool).
q Compression leakage through cylinder
head gasket
q Defective injection
q Defective piston, piston ring, or cylinder
liner
q Defective valve mechanism (Moving valve
system)
q Defect in electrical system
3. Since the common rail fuel injection system
controls the injector of each cylinder electroni-
cally, the operator can perform the reduced cyl-
inder mode operation easily with switches to
find out a defective cylinder.
a Perform the reduced cylinder mode opera-
tion with the engine mounted on the
machine or connected to INSITE (bench
test tool).
a Before performing, see "Testing method"
in the shop manual for the machine or
INSITE (bench test tool).
14 95E-5 Series
Testing leakage from pressure 3) Insert spacer G1 on return block (3) side
limiter and return rate from and tighten the removed joint bolt again.
a Be sure to fit the gaskets to both ends
injector 1
of the spacer.
a The locations of the fuel circuit parts are sub-
ject to machine models.
a Testing tools for leakage from pressure limiter
and return rate from injector

1 6151-51-8490 Spacer
2 6206-71-1770 Joint
3 07042-20108 Plug
G 4 Commercially available Hose
5 Commercially available Hose
6 Commercially available Measuring cylinder
7 Commercially available Stopwatch
4) Insert joint G2 on common rail (1) side and
a Prepare an oil pan of about 20 l to receive the tighten the removed joint bolt again.
fuel flowing out during the test. a Be sure to fit the gaskets to both ends
of the joint.
1. Preparation work 5) Remove spill hose connector joint (5) and
1) Remove spill hose (2) between common install plug G3.
rail (1) and injector. 3 Plug G3:
2) Remove tube (4) between common rail (1) 3.9 6.9 Nm {0.4 0.7 kgm}
and return block (3).
95E-5 Series 15
6) Connect test hose G4 to the end of joint 2. Testing leakage from pressure limiter
G2. 1) Lay test hose G4 so that it will not slacken
a Bind the connecting part of the test and put its end in the oil pan.
hose with a wire, etc. to prevent it 2) Connect INSITE (bench test tool) to the
from coming off. engine and set it so that it can check the
7) Connect test hose G5 to connector (6) engine speed.
side of spill hose (2). q Or set the installed equipment so that
a Bind the connecting part of the test it can check the engine speed.
hose with a wire, etc. to prevent it 3) Run the engine at the rated output.
from coming off. 4) After the engine speed is stabilized, test
the leakage in 1 minute with measuring
cylinder G6.
a You may test for 20 seconds and
judge by multiplying the result by 3.
a If the leakage from the pressure lim-
iter is in the following range, it is nor-
mal.
Engine speed Leakage
(rpm) (cc/min)
At rated output Max. 20
Reference:
A limit value is the value mentioned
above, but a standard value in nor-
8) The above is the preparation work for test- malcy is 0 cc/min. (no leak).
ing.
5) After finishing testing, stop the engine.
16 95E-5 Series
3. Testing return rate from injector

1) Lay test hose G5 so that it will not slacken
and put its end in the oil pan.
2) Connect INSITE (bench test tool) to the
engine and set it so that it can check the
engine speed.
3) Run the engine at the rated output.
4) After the engine speed is stabilized, test
the return rate in 1 minute with measuring
cylinder G6.
a You may test for 20 seconds and
judge by multiplying the result by 3.
a If the supply pump is not supplying
fuel, the engine speed may not rise.
In this case, record the engine speed,
too, during the test.
a If the return rate (spill) from the injec-
tor is in the following range, it is nor-
mal.
Rated output speed Return (Spill) limit
(rpm) (cc/min)
1,600 190
1,700 200
1,800 210
1,900 220
2,000 230
5) After finishing testing, stop the engine.
4. Work after finishing testing

After finishing all testing, remove the testing
tools and return the removed parts.
3 Joint (5): 3.9 6.9 Nm {0.4 0.7 kgm}
95E-5 Series 17
Bleeding air from fuel circuit 1
a If fuel is used up or if a fuel circuit part is

removed and installed, bleed air from the fuel
circuit according to the following procedure.
a The locations of the fuel circuit parts are sub-
ject to machine models.
a Fuel prefilter (1), priming pump (2) and air
bleeding plug (3) on the fuel prefilter side are
installed to the chassis.
1. Remove fuel pre-fuel filter (1) and fill it with

fuel.
a Fill the fuel filter with clean fuel and take
care that dirt will not enter it.
a Check that the cap is fitted to part (a)
(central hole) of the pre-fuel filter, and then
2. Install pre-fuel filter (1) to the filter head.
add fuel through part (b) (holes around the
a Apply engine oil thinly over the packing on
central hole).
the pre-fuel filter side.
a After filling the pre-fuel filter with fuel,
a After the packing of the pre-fuel filter
remove the cap from part (a).
touches the sealing face of the filter head,
a If clean fuel is not available, do not
tighten the fuel filter 3/4 turns.
remove the pre-fuel filter but fill it with the
fuel by operating priming pump (2).
a Do not add fuel to fuel main filter (4) exter-
nally.
18 95E-5 Series
3. Remove air bleeding plug (3) of the fuel prefil-

ter bracket and operate priming pump (2).
a Operate the priming pump until fuel flows
out of the plug hole. After checking that
fuel flows out, install the plug.
4. Remove air bleeding plug (5) of the fuel main

filter (4) and operate priming pump (2).
a Operate the priming pump until fuel flows
out of the plug hole. After checking that
fuel flows out, install the plug.
3 Air bleeding plug:
7.8 9.8 Nm {0.8 1.0 kgm}
5. Start the engine with the starting motor.

a The air in the high-pressure circuit is bled
automatically if the engine is cranked.
a If the engine does not start, there may be
still air in the low-pressure circuit. In this
case, repeat the above procedure from
step 3.
95E-5 Series 19
Testing fuel system for leakage 1 9. Inspect the fuel piping and devices for fuel
leakage.
k Very high pressure is generated in the high- a Inspect mainly around the high-pressure
pressure circuit of the fuel system. If fuel circuit parts coated with the color checker
leaks while the engine is running, it is dan- for fuel leakage.
gerous since it can catch fire. a If any fuel leakage is detected, repair it
After testing the fuel system or removing and inspect again from step 1.
its parts, test it for fuel leakage according a If no fuel leakage is detected, inspection is
to the following procedure. completed.
a Clean and degrease the engine and the parts
around it in advance so that you can test it eas-
ily for fuel leakage.
1. Spray color checker (developer) over the fuel

supply pump, common rail, fuel injector, and
joints of the high-pressure piping.
2. Run the engine at speed below 1,000 rpm and

stop it after its speed is stabilized.
3. Inspect the fuel piping and devices for fuel

leakage.
a Inspect mainly around the high-pressure
circuit parts coated with the color checker
for fuel leakage.
a If any fuel leakage is detected, repair it
and inspect again from step 1.
4. Run the engine at low idle.

leakage.
for fuel leakage.
6. Run the engine at high idle.

leakage.
for fuel leakage.
8. Run the engine at high idle and load it.

a When testing the engine mounted on the
machine, stall the torque converter or
relieve the oil from the hydraulic pump.
20 95E-5 Series
Testing and adjusting alternator Adjusting

belt tension 1 a If the deflection is out of the standard range,
adjust it according to the following procedure.
Testing
Press the intermediate point of the belt between 1. Loosen alternator fixing bolts (1) and (2).
alternator pulley and fan pulley with a finger and a Loosen fixing bolt (2) from the rear side of
measure deflection (a) of the belt. the engine.
a Pressing force: Approx. 58.8 N {Approx. 6 kg}
a Deflection (a): 7 10 mm
2. Adjust the tension of alternator belt (4) by turn-

ing adjustment bolt (3).
a Do not loosen double nut (5) at the adjust-
ment bolt end. (If you have loosened it,
apply LOCTITE (LT-2) to it when tighten-
ing it.)
Reference: If adjustment bolt (3) is tight-
ened (turned to the right),
al te rnato r b elt ( 4) is loo s-
ened. If the former is turned to
the left, the latter is tightened.
3. After adjusting the belt tension, tighten alterna-

tor fixing bolts (1) and (2).
4. Check again that the tension of alternator belt

(4) is in the standard range.
95E-5 Series 21
Handling controller voltage circuit1

1. When disconnecting or connecting a connector
between the engine controller and engine, be
sure to turn the starting switch OFF.
2. If a T-adapter is inserted in or connected to a

connector between the engine controller and
engine for troubleshooting, do not start the
engine.
a You may turn the starting switch to the
OFF or ON position but must not turn it to
the START position.
22 95E-5 Series
SEN02182-00
2006 KOMATSU
All Rights Reserved
24
SEN02183-00
ENGINE 1SHOP MANUAL
95E-5 Series
40 Troubleshooting 1
General information on troubleshooting
Points on troubleshooting ............................................................................................................................... 2
Error code and failure code table .................................................................................................................... 4
Information in troubleshooting table ................................................................................................................ 6
95E-5 Series 1
SEN02183-00 40 Troubleshooting
Points on troubleshooting 1
k When troubleshooting a machine, stop it in a level ground, and check that the lock pin, chocks,
and parking brake are securely fitted.
k When carrying out the operation with two or more workers, keep strictly to the agreed signals,
and do not allow any unauthorized person to come near.
k If the radiator cap is removed when the engine is hot, hot coolant may spurt out and cause
burns, so be sure to wait for the engine to cool down before starting troubleshooting.
k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
k When disconnecting wiring, always disconnect the negative () terminal of the battery first.
k When removing the plug or cap from a location which is under pressure from oil, water, or air,
always release the internal pressure first. When installing measuring equipment, be sure to con-
nect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to pre-
vent reoccurrence of the failure. When carrying out troubleshooting, an important point is of course to under-
stand the structure and function. However, a short cut to effective troubleshooting is to ask the operator
various questions to form some idea of possible causes of the failure that would produce the reported symp-
toms.
1. When carrying out troubleshooting, do not 3. Check before troubleshooting

hurry to disassemble the components. 1) Check for symptoms of any abnormality in
If components are disassembled immediately the machine and engine.
after any failure occurs: 2) Be sure to check the CHECKS BEFORE
q Parts that have no connection with the fail- STARTING items.
ure or other unnecessary parts will be dis- 3) Check other inspection items, if neces-
assembled. sary.
q It will become impossible to find the cause 4) Some other maintenance items can be
of the failure. checked externally, so check any item that
It will also cause a waste of manhours, parts, is considered to be necessary.
or oil or grease, and at the same time, will also 5) Check the controller for display of an error.
lose the confidence of the user or operator.
For this reason, when carrying out trouble- 4. Confirming failure
shooting, it is necessary to carry out thorough Confirm the extent of the failure yourself, and
prior investigation and to carry out trouble- judge whether to handle it as a real failure or
shooting in accordance with the fixed proce- as a problem with the method of operation, etc.
dure. a When operating the machine or engine to
reenact the troubleshooting symptoms, do
2. Points to ask user or operator not carry out any investigation or mea-
1) Have any other problems occurred apart surement that may make the problem
from the problem that has been reported? worse.
2) Was there anything strange about the
machine before the failure occurred? 5. Troubleshooting
3) Did the failure occur suddenly, or were Use the results of the investigation and inspec-
there problems with the machine condition tion in Items 2 4 to narrow down the causes
before this? of failure, then use the troubleshooting matrix
4) Under what conditions did the failure to locate the position of the failure exactly.
occur? a The basic procedure for troubleshooting is
5) Had any repairs been carried out before as follows.
the failure? When were these repairs car- 1) Start from the simple points.
ried out? 2) Start from the most likely points.
6) Has the same kind of failure occurred 3) Investigate other related parts or informa-
before? tion.
2 95E-5 Series
6. Measures to remove root cause of failure

Even if the failure is repaired, if the root cause
of the failure is not repaired, the same failure
will occur again. To prevent this, always inves-
tigate why the problem occurred. Then,
remove the root cause.
95E-5 Series 3
Error code and failure code table 1

(for construction equipment)
INSITE Machine failure Reference document
Failure phenomenon
error code code No.
111 CA111 ECM Critical Internal Failure
115 CA115 Eng. Ne and Bkup Speed Sensor Error
122 CA122 Charge Air Press Sensor High Error
123 CA123 Charge Air Press Sensor Low Error
131 CA131 Throttle Sensor High Error
132 CA132 Throttle Sensor Low Error
144 CA144 Coolant Temp. Sensor High Error
145 CA145 Coolant Temp. Sensor Low Error
153 CA153 Charge Air Temp. Sensor High Error
154 CA154 Charge Air Temp. Sensor Low Error
187 CA187 Sensor Sup. 2 Volt. Low Error
221 CA221 Ambient Air Press. Sensor High Error
222 CA222 Ambient Air Press. Sensor Low Error
227 CA227 Sensor Sup. 2 Volt. High Error
Troubleshooting of
234 CA234 Eng. Overspeed electrical system
238 CA238 Ne Speed Sensor Sup. Volt. Error (E-mode), Part 1
SEN02185-00
271 CA271 IMV Short Error
272 CA272 IMV Open Error
322 CA322 Injector #1 (L/B #1) System Open/Short Error
351 CA351 INJ. Drive Circuit Error
352 CA352 Sensor Sup. 1 Volt. Low Error
386 CA386 Sensor Sup. 1 Volt. High Error
431 CA431 Idle Validation SW Low error
432 CA432 Idle Validation Process error
435 CA435 Abnormality in engine oil pressure switch
441 CA441 Battery voltage low error
442 CA442 Battery voltage high error
449 CA449 Rail Press. Very High Error
451 CA451 Rail Press. Sensor High Error
452 CA452 Rail Press. Sensor Low Error
553 CA553 Rail Press. High Error
559 CA559 Rail Press. Low Error
Troubleshooting of
689 CA689 Eng. Ne Speed Sensor Error electrical system
731 CA731 Eng. Bkup Speed Sensor Phase Error (E-mode), Part 2
SEN02186-00
757 CA757 All Persistent Data Lost Error
778 CA778 Eng. Bkup Speed Sensor Error
1633 CA1633 KOMNET Dtalink Timeout Error
2185 CA2185 Throttle Sens. Sup. Volt. High Error
2186 CA2186 Throttle Sens. Sup. Volt. Low Error
4 95E-5 Series
INSITE Machine failure Reference document

Failure phenomenon
error code code No.
2249 CA2249 Rail Press. Very Low Error
2311 CA2311 Abnormality in IMV solenoid
2555 CA2555 Grid Heater Relay Volt. Low Error Troubleshooting of
electrical system
2556 CA2556 Grid Heater Relay Volt. High Error
(E-mode), Part 2
B@BAZG Eng. Oil press. Torque Derate SEN02186-00
B@BAZG Eng. Oil press. Low Speed Derate
B@BCNS Eng. Overheat
a INSITE error code:

An error code of 3 or 4 digits displayed on the INSITE (bench test tool) when the occurrence condition of
the failure is confirmed with the INSITE.
a Machine failure code:
An error code of 5 or 6 digits displayed on the machine monitor when the occurrence condition of the
failure is confirmed with the machine monitor, etc. on the machine side.
95E-5 Series 5
Information in troubleshooting table 1

a The following information is summarized in the troubleshooting table and the related electrical circuit
diagram. Before carrying out troubleshooting, understand that information fully.
Error code Failure code

Display on Display on applica- Trouble Problem that appears on engine
INSITE ble machine
Contents of
Contents of trouble detected by engine controller
trouble
Action of Action taken by engine controller to protect system or devices when engine controller detects
controller trouble
Problem that
appears on Problem that appears on engine as result of action taken by engine controller (shown above)
machine
Related
Information related to detected trouble or troubleshooting
information
Causes Standard value in normal state/Remarks on troubleshooting

<Contents of description>
Standard value in normal state to judge possible causes
Remarks on judgment
1
<Troubles in wiring harness>
Disconnection
Connector is connected imperfectly or wiring harness is
broken.
Ground fault
Wiring harness which is not connected to chassis ground
circuit is in contact with chassis ground circuit.
Hot short
Wiring harness which is not connected to power source
2 (24 V) circuit is in contact with power source (24 V) circuit.
Short circuit
Independent wiring harnesses are in contact with each
Possible causes other abnormally.
and standard Possible causes of trouble
value in normal (Given numbers are reference
state numbers, which do not indicate <Precautions for troubleshooting>
priority) (1) Method of indicating connector No. and handling of T-
adapter
Insert or connect T-adapter as explained below for trou-
bleshooting, unless otherwise specified.
3
If connector No. has no marks of male and female,
disconnect connector and insert T-adapters in both
male side and female side.
If connector No. has marks of male and female,
disconnect connector and connect T-adapter to only
male side or female side.
(2) Entry order of pin Nos. and handling of tester leads
Connect positive (+) lead and negative () lead of tester
as explained below for troubleshooting, unless otherwise
4 specified.
Connect positive (+) lead to pin No. or wiring harness
entered on front side.
Connect negative () lead to pin No. or wiring harness
entered on rear side.
6 95E-5 Series
Related circuit diagram
This drawing is a part of the electric circuit diagram related

to troubleshooting.
Connector No.: Indicates (Model Number of pins) and
(Color).
Connector No. and pin No. from each branching/merg-
ing point: Shows the ends of branch or source of merging
within the parts of the same wiring harness.
Arrow (): Roughly shows the location on the machine.
95E-5 Series 7
SEN02183-00
2006 KOMATSU
All Rights Reserved
8
SEN02185-00
ENGINE 1SHOP MANUAL
95E-5 Series
Troubleshooting of electrical system
(E-mode), Part 1
E-1 Code [111/CA111] ECM Critical Internal Failure ....................................................................................... 4
E-2 Code [115/CA115] Eng. Ne and Bkup Speed Sensor Error...................................................................... 7
E-3 Code [122/CA122] Charge Air Press Sensor High Error.......................................................................... 8
E-4 Code [123/CA123] Charge Air Press Sensor Low Error ........................................................................ 10
E-5 Code [131/CA131] Throttle Sensor High Error........................................................................................11
E-6 Code [132/CA132] Throttle Sensor Low Error........................................................................................ 14
E-7 Code [144/CA144] Coolant Temp. Sensor High Error............................................................................ 15
E-8 Code [145/CA145] Coolant Temp. Sensor Low Error............................................................................. 16
E-9 Code [153/CA153] Charge Air Temp. Sensor High Error ....................................................................... 18
E-10 Code [154/CA154] Charge Air Temp. Sensor Low Error...................................................................... 20
E-11 Code [187/CA187] Sensor Sup. 2 Volt. Low Error................................................................................ 21
E-12 Code [221/CA221] Ambient Air Press. Sensor High Error ................................................................... 22
E-13 Code [222/CA222] Ambient Air Press. Sensor Low Error .................................................................... 24
E-14 Code [227/CA227] Sensor Sup. 2 Volt. High Error............................................................................... 25
95E-5 Series 1
E-15 Code [234/CA234] Eng. Overspeed ..................................................................................................... 27

E-16 Code [238/CA238] Ne Speed Sensor Sup. Volt. Error ......................................................................... 28
E-17 Code [271/CA271] IMV Short Error ...................................................................................................... 30
E-18 Code [272/CA272] IMV Open Error...................................................................................................... 32
E-19 Code [322/CA322] Injector #1 (L/B #1) System Open/Short Error ....................................................... 34
E-23 Code [351/CA351] INJ. Drive Circuit Error ........................................................................................... 42
E-24 Code [352/CA352] Sensor Sup. 1 Volt. Low Error................................................................................ 45
E-25 Code [386/CA386] Sensor Sup. 1 Volt. High Error............................................................................... 46
E-26 Code [431/CA431] Idle Validation SW Low error.................................................................................. 48
E-27 Code [432/CA432] Idle Validation Process error .................................................................................. 48
E-28 Code [435/CA435] Abnormality in engine oil pressure switch.............................................................. 49
E-29 Code [441/CA441] Battery voltage low error ........................................................................................ 50
E-30 Code [442/CA442] Battery voltage high error....................................................................................... 50
2 95E-5 Series
E-1 Code [111/CA111] ECM Critical Internal Failure 1

Trouble ECM Critical Internal Failure
111 CA111
Contents of
Abnormality occurred in controller.
trouble
Action of
None in particular.
controller
Problem that
appears on Engine runs normally but it may stop during operation or may not be able to start.
machine
Related
Different machine models may have different connector Nos.
information
Cause Standard value in normal state/Remarks on troubleshooting

Check fuse or circuit breaker on machine side directly for defect.
1 Defective fuse (If fuse is broken or circuit breaker is turned OFF, circuit probably
has ground fault.)
a Prepare with starting switch OFF, then carry out troubleshoot-
Defective power supply cutout ing without turning starting switch ON.
2
relay Wiring harness between CE02 (female) Resis- 185
(55) (32) tance 265 z
ing without turning starting switch ON.
Wiring harness between CE02 (female) Resis-
Max. 1 z
(55) R23 (1) tance
Possible causes Wiring harness between CE02 (female) Resis-
Max. 1 z
and standard (55) R24 (1) tance
value in normal Wiring harness between CE02 (female) Resis-
state Max. 1 z
(32) R23 (2) tance
Disconnection in wiring Wiring harness between CE02 (female) Resis-
Max. 1 z
harness (32) R24 (2) tance
3
(Disconnection in wiring or Wiring harness between CE03 (female) (1) Resis-
defective contact in connector) Max. 1 z
T12 tance
Wiring harness between CE03 (female) (3) Resis-
Max. 1 z
R23 (5) tance
Wiring harness between CE03 (female) (3) Resis-
Max. 1 z
R24 (5) tance
Wiring harness between R23 (female) (3) Resis-
Max. 1 z
battery (+) tance
Max. 1 z
battery (+) tance
4 95E-5 Series

Wiring harness between CE02 (female) Resis- Min.
(55) R23 (1) and chassis ground tance 1 Mz
Ground fault in wiring harness Wiring harness between CE02 (female) Resis- Min.
Possible causes 4
(Short circuit with GND circuit) (32) R24 (2) and chassis ground tance 1 Mz
and standard
Wiring harness between CE03 (female) (3) Resis- Min.
value in normal
R23 (5) and chassis ground tance 1 Mz
state
Wiring harness between R23 (female) (3) Resis- Min.
battery (+) and chassis ground tance 1 Mz
a Prepare with starting switch OFF, turn starting switch ON and
carry out troubleshooting.
5 Defective engine controller
CE03 Voltage
Between (3) (1) 20 30 V
Note: The names and Nos. of the connectors of PC128/138US-8 are shown as examples.
95E-5 Series 5
Circuit diagram related to controller power supply (Case of PC128/138US-8)
6 95E-5 Series
E-2 Code [115/CA115] Eng. Ne and Bkup Speed Sensor Error 1

Trouble Eng. Ne and Bkup Speed Sensor Error
115 CA115
Contents of
Abnormality occurred in Ne speed sensor circuit and Bkup speed sensor circuit simultaneously.
trouble
Action of
None in particular.
controller
Problem that
Engine cannot be started (if engine has been stopped).
appears on
Engine stops (if engine has been running).
machine
Related
information

Defective Ne speed sensor
1 Carry out troubleshooting for code [689/CA689].
system
Defective Bkup speed sensor
2 Carry out troubleshooting for code [778/CA778].
system
Possible causes Defective mount of Ne speed Check mount of Ne speed sensor directly for defect (defective
3
and standard sensor installation of sensor, internal of flywheel, etc.)
value in normal Defective mount of Bkup Check mount of Bkup speed sensor directly for defect (defective
state 4
speed sensor installation of sensor, internal of supply pump, etc.)
Defective connection (Wrong Check Ne speed sensor and Bkup speed sensor directly for
5
connection) defective connection (wrong connection).
If causes 1 5 are not detected, engine controller may be defec-
6 Defective engine controller tive. (Since trouble is in system, troubleshooting cannot be car-
ried out.)
Reference: Bkup speed sensor = Cam speed sensor
95E-5 Series 7
E-3 Code [122/CA122] Charge Air Press Sensor High Error 1

Trouble Charge Air Press Sensor High Error
122 CA122
Contents of
Signal voltage in charge pressure sensor circuit is abnormally high.
trouble
Action of
Fixes charge pressure (400 kPa {4.08 kg/cm2}) and continues operation.
controller
Problem that
appears on Acceleration performance of engine drops.
machine
Related
information

Defective sensor power supply If code [187/CA187] or [227/CA227] is indicated, carry out trou-
1
system bleshooting for it first.
Prepare with starting switch OFF, then turn starting switch ON or
start engine and carry out troubleshooting.
Defective charge pressure PTIM Voltage
2 sensor Between (2) (4) Power supply 4.75 5.25 V
(Internal trouble)
Sensor voltage is measured with wiring harness connected.
Accordingly, if voltage is abnormal, check wiring harness and
controller, too, for another cause of trouble, and then judge.
Possible causes Disconnection in wiring har- Wiring harness between ENG1 (female) Resis-
Max. 1 z
and standard ness (19) PTIM (female) (1) tance
3
value in normal (Disconnection in wiring or Wiring harness between ENG1 (female) Resis-
state (36) PTIM (female) (2) tance
Wiring harness between ENG1 (female) Resis-
Max. 1 z
(48) PTIM (female) (4) tance
Wiring harness between ENG1 (female)
Resis- Min.
(19) PTIM (female) (1) and chassis
tance 1 Mz
ground
Ground fault in wiring harness
4
(Short circuit with GND circuit) Wiring harness between ENG1 (female) Resis- Min.
tance 1 Mz
ground
Resis- Min.
tance 1 Mz
ground
8 95E-5 Series

(19) PTIM (female) (1) and wiring har- Resis- Min.
ness between ENG1 (female) (36) PTIM tance 1 Mz
(female) (2)
Short circuit in wiring harness Wiring harness between ENG1 (female)
Possible causes 5
(With another wiring harness) (19) PTIM (female) (1) and wiring har- Resis- Min.
and standard ness between ENG1 (female) (48) PTIM tance 1 Mz
value in normal (female) (4)
state
Chassis ground between ENG1 (female)
(36) PTIM (female) (2) and chassis Resis- Min.
ground between ENG1 (female) (48) tance 1 Mz
PTIM (female) (4)
ENG1 Voltage
Between (36) (48) Power supply 4.75 5.25 V
Circuit diagram related to charge pressure sensor
95E-5 Series 9
E-4 Code [123/CA123] Charge Air Press Sensor Low Error 1

Trouble Charge Air Press Sensor Low Error
123 CA123
Contents of
Signal voltage in charge pressure sensor circuit is abnormally low.
trouble
Action of
Fixes charge pressure (400 kPa {4.08 kg/cm2}) and continues operation.
controller
Problem that
appears on Acceleration performance of engine drops.
machine
Related
information
Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard
value in normal Carry out troubleshooting for E-3 Code [122/CA122].
state
10 95E-5 Series
E-5 Code [131/CA131] Throttle Sensor High Error 1

Throttle sensor of accelerator pedal type

Trouble Throttle Sensor High Error
131 CA131
Contents of
Signal voltage in throttle sensor circuit is abnormally high.
trouble
Action of Sets throttle angle with signal other than throttle sensor signal and continues operation
controller (depending on each model)
Problem that
appears on Different problems occur on different machine models.
machine
Related
information
(Since this code is not set for the related machines, details are not described.)
95E-5 Series 11
Throttle sensor of fuel control dial type (Case of PC128/138US-8)

Trouble Throttle Sensor High Error
131 CA131
Contents of
Signal voltage in throttle sensor circuit is abnormally high.
trouble
Problem that
machine
Related
information

Defective sensor power supply If code [2185/CA2185] or [2186/CA2186] is indicated, carry out
1
system troubleshooting for it first.
Defective fuel control dial P20 (male) Resistance

2
(Internal trouble) Between (1) (3) 4.0 6.0 kz
Between (2) (1) 0.25 5.0 kz
Between (2) (3) 0.25 5.0 kz
Disconnection in wiring har- Wiring harness between CE2 (female) (27) Resis-
Max. 1 z
ness P20 (female) (1) tance
3
Possible causes (Disconnection in wiring or Wiring harness between CE2 (female) (35) Resis-
and standard P20 (female) (2) tance
value in normal Wiring harness between CE2 (female) (28) Resis-
state Max. 1 z
P20 (female) (3) tance
Ground fault in wiring harness P20 (female) (1) and chassis ground tance 1 Mz
4
(Short circuit with GND circuit) Wiring harness between CE2 (female) (35) Resis- Min.
P20 (female) (2) and chassis ground tance 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
5 Defective engine controller CE2 Voltage
Between (35) (28) Signal 0.5 4.5 V
12 95E-5 Series
Circuit diagram related to throttle sensor of fuel control dial type (Case of PC128-138US-8)
95E-5 Series 13
E-6 Code [132/CA132] Throttle Sensor Low Error 1

Trouble Throttle Sensor Low Error
132 CA132
Contents of
Signal voltage in throttle sensor circuit is abnormally low.
trouble
Action of Sets throttle angle with signal other than throttle signal and continues operation (depending on each
controller model).
Problem that
machine
Related
information

and standard
state
14 95E-5 Series
E-7 Code [144/CA144] Coolant Temp. Sensor High Error 1

Trouble Coolant Temp. Sensor High Error
144 CA144
Contents of
Signal voltage in coolant temperature sensor circuit is abnormally high.
trouble
Action of
Fixes coolant temperature (90C) and continues operation.
controller
Problem that
appears on
machine
Related
information

Defective coolant temperature ing without turning starting switch ON.
1
sensor (Internal trouble) TWTR (male) Coolant temperature Resistance
Between (1) (2) 10 100C 0.6 20 kz
Disconnection in wiring har- ing without turning starting switch ON.
ness (Disconnection in wiring Wiring harness between ENG1 (female) Resis-
2 Max. 1 z
Possible causes or defective contact in connec- (47) TWTR (female) (1) tance
and standard tor) Wiring harness between ENG1 (female) Resis-
value in normal Max. 1 z
(49) TWTR (female) (2) tance
state
3
(47) TWTR (female) (1) and chassis
tance 1 Mz
ground
ENG1 (female) Coolant temperature Resistance
Between (47) (49) 10 100C 0.6 20 kz
Circuit diagram related to coolant temperature sensor
95E-5 Series 15
E-8 Code [145/CA145] Coolant Temp. Sensor Low Error 1

Trouble Coolant Temp. Sensor Low Error
145 CA145
Contents of
Signal voltage in coolant temperature sensor circuit is abnormally low.
trouble
Action of
Fixes coolant temperature (90C) and continues operation.
controller
Problem that
appears on
machine
Related
information

and standard
value in normal Carry out troubleshooting E-7 Code [144/CA144].
state
16 95E-5 Series
E-9 Code [153/CA153] Charge Air Temp. Sensor High Error 1

Trouble Charge Air Temp. Sensor High Error
153 CA153
Contents of
Signal voltage in charge temperature sensor circuit is abnormally high.
trouble
Action of
Fixes charge temperature (intake air temperature) (70C) and continues operation.
controller
Problem that
appears on
machine
Related
information

Intake air
Defective charge temperature PTIM (male) Resistance
1 temperature
sensor (Internal trouble)
Between (3) (4) 10 100C 0.5 20 kz
Between (3)
All range Min. 1 Mz
chassis ground
Disconnection in wiring ing without turning starting switch ON.
Possible causes harness Wiring harness between ENG1 (female) Resis-
2 Max. 1 z
and standard (Disconnection in wiring or (11) PTIM (female) (3) tance
value in normal defective contact in connector) Wiring harness between ENG1 (female) Resis-
state Max. 1 z
(48) PTIM (female) (4) tance
3
tance 1 Mz
ground
4 Defective engine controller Intake air
ENG1 (female) Resistance
temperature
Between (11) (48) 10 100C 0.5 20 kz
18 95E-5 Series
Circuit diagram related to charge temperature sensor
95E-5 Series 19
E-10 Code [154/CA154] Charge Air Temp. Sensor Low Error 1

Trouble Charge Air Temp. Sensor Low Error
154 CA154
Contents of
Signal voltage in charge temperature sensor circuit is abnormally low.
trouble
Action of
Fixes charge temperature (intake air temperature) (70C) and continues operation.
controller
Problem that
appears on
machine
Related
information

and standard
state
20 95E-5 Series
E-11 Code [187/CA187] Sensor Sup. 2 Volt. Low Error 1

Trouble Sensor Sup. 2 Volt. Low Error
187 CA187
Contents of
Signal voltage in sensor power supply 2 (5 V) circuit is abnormally low.
trouble
Operates Bkup speed sensor with signals of Ne speed sensor.
Action of Sets atmospheric pressure sensor to default value (52.44 kPa {0.53 kg/cm2}) and continues opera-
controller tion.
Fixes charge pressure sensor value (400 kPa {4.08 kg/cm2}) and continues operation.
Problem that
appears on Output drops.
machine
Related
information
Possible causes Causes Standard value in normal state/Remarks on troubleshooting

and standard
state
95E-5 Series 21
E-12 Code [221/CA221] Ambient Air Press. Sensor High Error 1

Trouble Ambient Air Press. Sensor High Error
221 CA221
Contents of
Signal voltage in atmospheric pressure sensor circuit is abnormally high.
trouble
controller tion.
Problem that
machine
Related
information

1
PAMB Voltage
Defective atmospheric pres-
2 sure sensor
(Internal trouble) Between (2) (3) Signal 0.3 4.7 V
Possible causes Wiring harness between ENG1 (female) Resis-
Disconnection in wiring har- Max. 1 z
and standard (36) PAMB (female) (1) tance
ness
value in normal 3
(Disconnection in wiring or Wiring harness between ENG1 (female) Resis-
state Max. 1 z
defective contact in connector) (20) PAMB (female) (2) tance
Max. 1 z
(48) PAMB (female) (3) tance
Resis- Min.
(36) PAMB (female) (1) and chassis
tance 1 Mz
ground
4
tance 1 Mz
ground
Resis- Min.
tance 1 Mz
ground
22 95E-5 Series

(36) PAMB (female) (1) and wiring har- Resis- Min.
ness between ENG1 (female) (20) PAMB tance 1 Mz
(female) (2)
5
(With another wiring harness) (36) PAMB (female) (1) and wiring har- Resis- Min.
Possible causes
and standard ness between ENG1 (female) (48) PAMB tance 1 Mz
value in normal (female) (3)
state Wiring harness between ENG1 (female)
(20) PAMB (female) (2) and wiring har- Resis- Min.
ness between ENG1 (female) (48) PAMB tance 1 Mz
(female) (3)
or start engine and carry out troubleshooting.
6 Defective engine controller ENG1 Voltage
Between (36) (48) 4.75 5.25 V
Between (20) (48) 0.3 4.7 V
Circuit diagram related to atmospheric pressure sensor
95E-5 Series 23
E-13 Code [222/CA222] Ambient Air Press. Sensor Low Error 1

Trouble Ambient Air Press. Sensor Low Error
222 CA222
Contents of
Signal voltage in atmospheric pressure sensor circuit is abnormally low.
trouble
Action of
Sets oil pressure to default value (52.44 kPa {0.53 kg/cm2}) and continues operation.
controller
Problem that
machine
Related
information

and standard
state
24 95E-5 Series
E-14 Code [227/CA227] Sensor Sup. 2 Volt. High Error 1

Trouble Sensor Sup. 2 Volt. High Error
227 CA227
Contents of
Signal voltage in sensor power supply 2 (5 V) circuit is abnormally high.
trouble
Operates Bkup speed sensor with signals of Ne speed sensor.
controller tion.
Fixes charge pressure sensor value (400 kPa {4.08 kg/cm2}) and continues operation.
Problem that
machine
Related
information

If another failure code is indicated, carry out troubleshooting for
1 Defective related system
it.
Disconnect devices Bkup speed sensor CAM connector
Defective sensor (Internal trou- at right in order. If Atmospheric
2 error code disap- PAMB connector
ble) pressure sensor
pears when a device
is disconnected, that Charge pressure
device has a defect PTIM connector
sensor
in it.
ness Wiring harness between ENG1 (female) Resis-
3 Max. 1 z
(Disconnection in wiring or (36) each sensor (female) tance
defective contact in connector) Wiring harness between ENG1 (female) Resis-
Possible causes Max. 1 z
and standard (48) each sensor (female) tance
value in normal a Prepare with starting switch OFF, then carry out troubleshoot-
state ing without turning starting switch ON.
Resis- Min.
Ground fault in wiring harness (36) each sensor (female) and chassis
4 tance 1 Mz
(Short circuit with GND circuit) ground
Resis- Min.
(48) each sensor (female) and chassis
tance 1 Mz
ground
5
(With another wiring harness) (36) each sensor (female) and Resis- Min.
Wiring harness between ENG1 (female) tance 1 Mz
(48) each sensor (female)
ENG1 Voltage
Between (36) (48) 4.75 5.25V
95E-5 Series 25
Circuit diagram related to sensor power supply 2 (5 V)
26 95E-5 Series
E-15 Code [234/CA234] Eng. Overspeed 1

Trouble Eng. Overspeed
234 CA234
Contents of
Engine speed is above operating range.
trouble
Action of
Limits fuel injection rate until engine speed lowers to operating range.
controller
Problem that
appears on Engine speed fluctuates.
machine
Related
information

Possible causes it.
and standard Way of use may be improper. Teach proper way of use to opera-
value in normal 2 Improper way of use
tor.
state
If causes 1 and 2 are not detected, engine controller may be
3 Defective engine controller defective. (Since trouble is in system, troubleshooting cannot be
carried out.)
95E-5 Series 27
E-16 Code [238/CA238] Ne Speed Sensor Sup. Volt. Error 1

Trouble Ne Speed Sensor Sup. Volt. Error
238 CA238
Contents of
Abnormality occurred in Ne speed sensor power supply (5 V) circuit.
trouble
Action of
Controls Ne speed sensor with signals of Bkup speed sensor.
controller
Problem that
Running engine stops (when Bkup speed sensor is also abnormal).
appears on
Stopped engine cannot be started (when Bkup speed sensor is also abnormal).
machine
Related
information

Disconnect devices
Defective Ne speed sensor at right in order. If
1 error code disap-
(Internal trouble)
pears when a device Ne speed sensor NE connector
is disconnected, that
device has a defect
in it.
2 Max. 1 z
or defective contact in connec- (26) NE (female) (1) tance
Possible causes tor) Wiring harness between ENG1 (female) Resis-
Max. 1 z
and standard (44) NE (female) (2) tance
Ground fault in wiring harness Wiring harness between ENG1 (female) Resis- Min.
3
(Short circuit with GND circuit) (26) NE (female) (1) and chassis ground tance 1 Mz
Wiring harness between ENG1 (female) Resis- Min.
(44) NE (female) (2) and chassis ground tance 1 Mz
Short circuit in wiring harness
4 Wiring harness between ENG1 (female)
(with another wiring harness) Resis- Min.
(26) NE (female) (1) and between ENG1
tance 1 Mz
(female) (44) NE (female) (2)
ENG1 Voltage
Between (26) (44) 4.75 5.25 V
28 95E-5 Series
Circuit diagram related to Ne speed sensor power supply
95E-5 Series 29
E-17 Code [271/CA271] IMV Short Error 1

Trouble IMV Short Error
271 CA271
Contents of
There is short circuit in IMV circuit of supply pump.
trouble
Action of
None in particular.
controller
Problem that
appears on
machine
Related
information

Defective supply pump IMV PREG (male) Resistance
1
(Internal trouble) Between (1) (2) 2.3 5.3 z
Between (1), (2) chassis
Min. 1 Mz
ground
Ground fault in wiring harness Wiring harness between ENG1 (female) Resis- Min.
2
(Short circuit with GND circuit) (10) PREG (female) (2) tance 1 Mz
Possible causes
(14) PREG (female) (1) tance 1 Mz
and standard
value in normal a Prepare with starting switch OFF, then turn starting switch ON
state and carry out troubleshooting.
Hot short (Short circuit with (10) PREG (female) (2) and chassis Voltage Max. 1V
3
24V circuit) in wiring harness ground
(14) PREG (female) (1) and chassis Voltage Max. 1V
ground
Between (10) (14) 2.3 5.3 z
Min. 1 Mz
ground
30 95E-5 Series
Circuit diagram related to supply pump IMV
95E-5 Series 31
E-18 Code [272/CA272] IMV Open Error 1

Trouble IMV Open Error
272 CA272
Contents of
There is disconnection in IMV circuit of supply pump.
trouble
Action of
None in particular.
controller
Problem that
appears on
machine
Related
information

Defective supply pump IMV PREG (male) Resistance
1
(Internal disconnection) Between (1) (2) 2.3 5.3 z
Min. 1 Mz
ground
2 Max. 1 z
(Disconnection in wiring or (10) PREG (female) (2) tance
(14) PREG (female) (1) tance
and standard
Resis- Min.
Ground fault in wiring harness (10) PREG (female) (2) and chassis
3 tance 1 Mz
Resis- Min.
(14) PREG (female) (1) and chassis
tance 1 Mz
ground
Between (10) (14) 2.3 5.3 z
Between (10) (14) chassis
Min. 1 Mz
ground
32 95E-5 Series
Circuit diagram related to supply pump IMV
95E-5 Series 33
E-19 Code [322/CA322] Injector #1 (L/B #1) System Open/Short Error 1

Trouble Injector #1 (L/B #1) System Open/Short Error
322 CA322
Contents of
There is disconnection or short circuit in injector #1 circuit.
trouble
Action of
None in particular.
controller
Problem that
Output drops.
appears on
Rotation is unstable.
machine
Related
information

Defective injector #1 CN1 (male) Resistance
1
(Internal trouble) Between (1) (2) 0.4 1.1 z
Min. 1 Mz
ground
2 Max. 1 z
(Disconnection in wiring or (57) CN1 (female) (1) tance
Max. 1 z
(53) CN1 (female) (2) tance
Possible causes
and standard a Prepare with starting switch OFF, then carry out troubleshoot-
value in normal ing without turning starting switch ON.
Resis- Min.
Ground fault in wiring harness (57) CN1 (female) (1) and chassis
3 tance 1 Mz
Resis- Min.
(53) CN1 (female) (2) and chassis
tance 1 Mz
ground
Defective injector or wiring har- If another failure code for injector abnormality is displayed, carry
4
ness of another cylinder out troubleshooting for it.
Between (57) (53) 0.4 1.1 z
Min. 1 Mz
ground
34 95E-5 Series
Circuit diagram related to injector #1
95E-5 Series 35

324 CA324
Contents of
trouble
Action of
None in particular.
controller
Problem that
Output drops.
appears on
machine
Related
information

Defective injector #3 (Internal CN3 (male) Resistance
1
trouble) Between (1) (2) 0.4 1.1 z
Min. 1 Mz
ground
2 Max. 1 z
or defective contact in connec- (55) CN3 (female) (1) tance
tor) Wiring harness between ENG1 (female) Resis-
Max. 1 z
Possible causes
Resis- Min.
3 tance 1 Mz
Resis- Min.
tance 1 Mz
ground
4
Between (55) (59) 0.4 1.1 z
Min. 1 Mz
ground
36 95E-5 Series
95E-5 Series 37

331 CA331
Contents of
trouble
Action of
None in particular.
controller
Problem that
Output drops.
appears on
machine
Related
information

1
Min. 1 Mz
ground
2 Max. 1 z
Max. 1 z
Possible causes
Resis- Min.
3 tance 1 Mz
Resis- Min.
tance 1 Mz
ground
4
Between (45) (58) 0.4 1.1 z
Min. 1 Mz
ground
38 95E-5 Series
95E-5 Series 39

332 CA332
Contents of
trouble
Action of
None in particular.
controller
Problem that
Output drops.
appears on
machine
Related
information

1
Min. 1 Mz
ground
2 Max. 1 z
Max. 1 z
Possible causes
Resis- Min.
3 tance 1 Mz
Resis- Min.
tance 1 Mz
ground
4
Between (56) (51) 0.4 1.1 z
Min. 1 Mz
ground
40 95E-5 Series
95E-5 Series 41
E-23 Code [351/CA351] INJ. Drive Circuit Error 1

Trouble INJ. Drive Circuit Error
351 CA351
Contents of
Abnormality occurred in injector drive circuit.
trouble
Action of
Limits output and continues operation (Limits common rail pressure).
controller
Problem that
machine
Related
information

If another failure code (code of abnormality in injector system) is
indicated, carry out troubleshooting for it.
Check fuse or circuit breaker on machine side directly for defect.
2 Defective fuse (If fuse is broken or circuit breaker is turned OFF, circuit probably
has ground fault.)
Defective power supply cutout ing without turning starting switch ON.
3
relay Wiring harness between CF02 (female) Resis- 185
(55) (32) tance 265 z
Wiring harness between CF02 (female) Resis-
Max. 1 z
Possible causes (55) R23 (1) tance
and standard Wiring harness between CF02 (female) Resis-
Max. 1 z
value in normal (55) R24 (1) tance
state Wiring harness between CF02 (female) Resis-
Max. 1 z
(32) R23 (2) tance
Disconnection in wiring Wiring harness between CF02 (female) Resis-
Max. 1 z
harness (32) R24 (2) tance
4
(Disconnection in wiring or Wiring harness between CF03 (female) (1) Resis-
T12 tance
Wiring harness between CF03 (female) (3) Resis-
Max. 1 z
R23 (5) tance
Wiring harness between CF03 (female) (3) Resis-
Max. 1 z
R24 (5) tance
Max. 1 z
battery (+) tance
Max. 1 z
battery (+) tance
42 95E-5 Series

Wiring harness between CF02 (female) Resis- Min.
Ground fault in wiring harness Wiring harness between CF02 (female) Resis- Min.
Possible causes 5
(Short circuit with GND circuit) (32) R24 (2) and chassis ground tance 1 Mz
and standard
Wiring harness between CF03 (female) (3) Resis- Min.
value in normal
state
Wiring harness between CF03 (female) (3) Resis- Min.
CF03 Voltage
Between (3) (1) 20 30 V
95E-5 Series 43
Circuit diagram related to controller power supply (case of PC128/138US-8)
44 95E-5 Series
E-24 Code [352/CA352] Sensor Sup. 1 Volt. Low Error 1

Trouble Sensor Sup. 1 Volt. Low Error
352 CA352
Contents of
Signal voltage in sensor power supply 1 (5 V) circuit is abnormally low.
trouble
Action of Limits output of common rail pressure sensor and continues operation (Limits common rail pres-
controller sure).
Problem that
machine
Related
information

and standard
state
95E-5 Series 45
E-25 Code [386/CA386] Sensor Sup. 1 Volt. High Error 1

Trouble Sensor Sup. 1 Volt. High Error
386 CA386
Contents of
Signal voltage in sensor power supply 1 (5 V) circuit is abnormally high.
trouble
Action of Limits output of common rail pressure sensor and continues operation (Limits common rail pres-
controller sure).
Problem that
machine
Related
information

it.
Disconnect devices
Defective sensor (Internal trou- at right in order. If
2 error code disap-
ble) Common rail pres-
pears when a device PFUEL connector
sure sensor
device has a defect
in it.
3 Max. 1 z
(Disconnection in wiring or (36) PFUEL (female) (1) tance
and standard (48) PFUEL (female) (3) tance
Resis- Min.
Ground fault in wiring harness (36) PFUEL (female) (1) and chassis
4 tance 1 Mz
Wiring harness between CE01 (female)
Resis- Min.
(48) PFUEL (female) (3) and chassis
tance 1 Mz
ground
5
(With another wiring harness) (36) PFUEL (female) (1) and Resis- Min.
wiring harness between ENG1 (female) tance 1 Mz
(48) PFUEL (female) (3)
ENG1 Voltage
Between (36) (48) 4.75 5.25V
46 95E-5 Series
Circuit diagram related to sensor power supply 1 (5 V)
95E-5 Series 47
E-26 Code [431/CA431] Idle Validation SW Low error 1


Trouble Idle Validation SW Low error
431 CA431
Contents of
Abnormality occurred in idle validation switch circuit
trouble
Action of
Sets throttle angle to certain value and continues operation (depending on each model).
controller
Problem that
appears on
machine
Related
information
E-27 Code [432/CA432] Idle Validation Process error 1

Trouble Idle Validation Process error
432 CA432
Contents of
Abnormality occurred in processing of idle validation switch circuit.
trouble
Action of
Sets throttle angle to certain value and continues operation (depending on each model).
controller
Problem that
appears on
machine
Related
information

and standard
state
48 95E-5 Series
E-28 Code [435/CA435] Abnormality in engine oil pressure switch 1

Trouble Abnormality in engine oil pressure switch
435 CA435
Contents of
Abnormality occurred in engine oil pressure switch signal circuit.
trouble
Action of
None in particular.
controller
Problem that
appears Engine oil pressure switch-based engine protection function does not function.
on machine
Related
information

a Prepare with starting switch OFF, then carry out troubleshooting
Defective engine oil pressure without turning starting switch ON.
1
switch POIL (Male) Resistance
Between (1) chassis ground Max. 1 z
Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting
ness without turning starting switch ON.
2 (Disconnection in wiring or
Possible defective contact in connec- Wiring harness between ENG1 (female) (32) Resis-
Max. 1 z
tor) POIL (female) (1) tance
causes and
standard value a Troubleshoot with starting switch OFF, then carry out trouble-
in normal state shooting without turning starting switch ON.
Short circuit in wiring harness Wiring harness among all pins between
3
(With another wiring harness) ENG1 (female) (32) ENG1 (female) Resis- Min.
(With all connectors of wiring harness distance 1 Mz
connected)
without turning starting switch ON.
ENG1 (Female) Resistance
Between (32) chassis ground Max. 1 z
Circuit diagram related to engine oil switch
95E-5 Series 49
E-29 Code [441/CA441] Battery voltage low error 1

Trouble Battery voltage low error
441 CA441
Contents of
Power supply voltage is abnormally low.
trouble
Action of
None in particular.
controller
Problem that
appears on Engine continues operation normally, but it may stop during operation or may not be able to start.
machine
Related
information

and standard
state
E-30 Code [442/CA442] Battery voltage high error 1

Trouble Battery voltage high error
442 CA442
Contents of
Power supply voltage is abnormally high.
trouble
Action of
None in particular.
controller
Problem that
machine
Related
information

and standard
state
50 95E-5 Series
SEN02185-00
2006 KOMATSU
All Rights Reserved
52
SEN02186-00
ENGINE 1SHOP MANUAL
95E-5 Series
Troubleshooting of electrical system
(E-mode), Part 2
E-31 Code [449/CA449] Rail Press. Very High Error...................................................................................... 3
E-32 Code [451/CA451] Rail Press. Sensor High Error.................................................................................. 4
E-33 Code [452/CA452] Rail Press. Sensor Low Error .................................................................................. 6
E-34 Code [553/CA553] Rail Press. High Error .............................................................................................. 7
E-35 Code [559/CA559] Rail Press. Low Error............................................................................................... 8
E-36 Code [689/CA689] Eng. Ne Speed Sensor Error ................................................................................. 12
E-37 Code [731/CA731] Eng. Bkup Speed Sensor Phase Error .................................................................. 14
E-38 Code [757/CA757] All Persistent Data Lost Error ................................................................................ 15
E-39 Code [778/CA778] Eng. Bkup Speed Sensor Error.............................................................................. 16
E-40 Code [1633/CA1633] KOMNET Dtalink Timeout Error......................................................................... 18
E-41 Code [2185/CA2185] Throttle Sens. Sup. Volt. High Error................................................................... 19
E-42 Code [2186/CA2186] Throttle Sens. Sup. Volt. Low Error ................................................................... 22
E-43 Code [2249/CA2249] Rail Press. Very Low Error................................................................................. 23
E-44 Code [2311/CA2311] Abnormality in IMV solenoid............................................................................... 24
95E-5 Series 1
E-45 Code [2555/CA2555] Grid Heater Relay Volt. Low Error...................................................................... 26

E-46 Code [2556/CA2556] Grid Heater Relay Volt. High Error..................................................................... 28
E-48 Code [(---)/B@BAZG] Eng. Oil press. Torque Derate .......................................................................... 30
E-47 Code [(---)/B@BAZG] Eng. Oil press. Low Speed Derate ................................................................... 30
E-49 Code [(---)/B@BCNS] Eng. Overheat .................................................................................................. 31
2 95E-5 Series
E-31 Code [449/CA449] Rail Press. Very High Error 1

Trouble Rail Press. Very High Error
449 CA449
Contents of
Common rail pressure sensor circuit detected abnormally high pressure (level 2).
trouble
Action of
controller
Problem that
machine
Related
information

and standard
state
95E-5 Series 3
E-32 Code [451/CA451] Rail Press. Sensor High Error 1

Trouble Rail Press. Sensor High Error
451 CA451
Contents of
Signal voltage in common rail pressure sensor circuit is abnormally high.
trouble
Action of
controller
Problem that
machine
Related
information

1
PFUEL Voltage
Defective common rail pres-
2 sure sensor
(Internal trouble) Between (2) (3) Signal 0.25 4.6 V
Possible causes Wiring harness between ENG1 (female) Resis-
Disconnection in wiring har- Max. 1 z
and standard (36) PFUEL (female) (1) tance
ness
value in normal 3
state Max. 1 z
defective contact in connector) (29) PFUEL (female) (2) tance
Max. 1 z
(48) PFUEL (female) (3) tance
Resis- Min.
tance 1 Mz
ground
4
tance 1 Mz
ground
Resis- Min.
tance 1 Mz
ground
4 95E-5 Series

(36) PFUEL (female) (1) and Resis- Min.
(29) PFUEL (female) (2)
5
(With another wiring harness) (36) PFUEL (female) (1) and Resis- Min.
Possible causes
and standard wiring harness between ENG1 (female) tance 1 Mz
value in normal (48) PFUEL (female) (3)
(29) PFUEL (female) (2) and Resis- Min.
wiring harness between ENG (female) (48) tance 1 Mz
PFUEL (female) (3)
6 Defective engine controller ENG1 Voltage
Between (36) (48) 4.75 5.25 V
Between (29) (48) 0.25 4.6 V
Circuit diagram related to common rail pressure sensor
95E-5 Series 5
E-33 Code [452/CA452] Rail Press. Sensor Low Error 1

Trouble Rail Press. Sensor Low Error
452 CA452
Contents of
Signal voltage in common rail pressure sensor circuit is abnormally low.
trouble
Action of
controller
Problem that
machine
Related
information

and standard
state
6 95E-5 Series
E-34 Code [553/CA553] Rail Press. High Error 1

Trouble Rail Press. High Error
553 CA553
Contents of
Common rail pressure sensor circuit detected abnormally high pressure (level 1).
trouble
Action of
None in particular.
controller
Problem that
machine
Related
information

it.
Check fuel used directly
2 Use of improper fuel
(for high viscosity).
Possible causes Defective electrical system of Common rail pressure sensor may have electric trouble. Carry
3
and standard common rail pressure sensor out troubleshooting for code [451/CA451] (E-32).
value in normal Defective mechanical system
state Check mechanical system of common rail pressure sensor
4 of common rail pressure sen-
directly.
sor
Check overflow valve directly for broken spring, worn seat, and
5 Defective overflow valve
stuck ball.
6 Clogging of overflow piping Check overflow piping directly for clogging.
7 Defective pressure limiter Check pressure limiter directly for mechanical defect.
95E-5 Series 7
E-35 Code [559/CA559] Rail Press. Low Error 1

Trouble Rail Press. Low Error
559 CA559
Contents of
Supply pump does not feed fuel (level 1).
trouble
Action of
Limits common rail pressure.
controller
Problem that
machine
Related
information

it.
2 Use of improper fuel Check fuel used directly (for high viscosity).
3 Clogging of fuel filter a If a fuel filter is clogged, replace it.
a For contents of troubleshooting, see Note 1. For check of pres-
sure in fuel low-pressure circuit, see Testing and adjusting,
Defective low-pressure circuit "Testing fuel pressure".
4
device Pressure in fuel low-pressure
circuit Min. 0.15 MPa {Min. 1.5 kg/cm2}
(At high idle or rated (stall) load)
Supply pump EMV may have electric trouble. Carry out trouble-
Defective electrical system of
5 shooting for following codes [271/CA271] (E-17), [272/CA272]
supply pump EMV
(E-18).
Defective common rail pres- Common rail pressure sensor may be defective. Check wiring
Possible causes 6
sure sensor harness for damage.
and standard
value in normal a For testing of leakage from pressure limiter, see Testing and
state adjusting, "Testing leakage from pressure limiter and return
7 Defective pressure limiter rate from injector".
Leakage from pressure limiter
Max. 10 cc/min
(At stall load)
a For testing of return rate (spill) from injector, see Testing and
adjusting, "Testing leakage from pressure limiter and return
rate from injector".
Speed at rated operation
Return (Spill) limit from injector
(at stall)
8 Defective injector 1,600 rpm 960 cc/min
1,700 rpm 1,020 cc/min
1,800 rpm 1,080 cc/min
1,900 rpm 1,140 cc/min
2,000 rpm 1,200 cc/min
9 Defective supply pump If causes 1 8 are not detected, supply pump may be defective.
<How to use check sheet>

Carry out the above troubleshooting and take a record of the contents of the attached Check sheet for no-
pressure feed.
8 95E-5 Series
Note 1: Check the low-pressure circuit parts for the following items.
1) Fuel level
2) Clogging of fuel tank breather
3) Sticking and wear of feed pump and clogging of filter
4) Leakage through and clogging of low-pressure fuel piping
6) Clogging of fuel filter
95E-5 Series 9
Check sheet for no-pressure feed
Model Work No.

Machine serial No. # Date of check / /
Engine Service meter h
Engine serial No. # Worker's name
A. Visual check Good NG

1 Fuel leakage to outside
2 Clogging of fuel tank breather
B. Check with machine monitor (Fault history function, monitoring function, and reduced cylinder mode function) Good NG
3 Check of error/failure code / / / /
Check of monitoring information
Standard value
Code Displayed item Checking condition Unit Measured value Good NG
(Reference value)
Low idle rpm <By models>
*1 Engine speed High idle rpm <By models>
Equivalent to rating <By models> rpm <By models>
Low idle % 0
*2 Throttle opening
High idle % 100
*3 Fuel injection command Equivalent to rating <By models> mm3
Common rail pressure
4 *4 Equivalent to rating <By models> MPa
command
Common rail fuel
*5 Equivalent to rating <By models> MPa
pressure
Low idle CA
Fuel injection timing
*6 High idle CA
command
Equivalent to rating <By models> CA
*7 Boost pressure Equivalent to rating <By models> kPa
Engine coolant
*8 Low idle C
temperature
*9 Fuel temperature Low idle C
Check of reduced cylinder mode operation (Engine speed)
Standard value
Function Reduced cylinder Checking condition Unit Measured value Good NG
(Reference value)
5 No. 1 cylinder Low idle rpm
No. 2 cylinder Low idle rpm
*10
C. Check of fuel circuit pressure Standard value

Checking condition Unit Measured value Good NG
(Reference value)
MPa
6 Fuel low-pressure circuit pressure High idle or rated (stall) load Min. 0.15 {Min. 1.5}
{kg/cm2}
D. Check of strainers and filters Good NG

7 Visual check of fuel filter
E.Check of leakage and return rate Standard value

Checking condition Unit Measured value Good NG
(Reference value)
8 Leakage through pressure limiter Equivalent to rating <By models> cc/min Max. 10
Equivalent to rating <By models>
cc/min 960
1,600 rpm
cc/min 1,020
1,700 rpm
Speed:
9 Return rate from injector cc/min 1,080
1,800 rpm
Return rate:
cc/min 1,140
1,900 rpm
cc/min 1,200
2,000 rpm
10 95E-5 Series
*1 *10:
When inspecting with INSITE (bench test tool), see Operation and Maintenance Manual (Testing
method).
When inspecting with the monitoring function of the machine, use the codes specified for each machine
model.
Equivalent to rating <By models>:
When inspecting the engine unit on the bench, operate it under a load equivalent to the rating. When
the engine is installed to the machine, however, the operation load equivalent to the rating depends on
the machine model.
95E-5 Series 11
E-36 Code [689/CA689] Eng. Ne Speed Sensor Error 1

Trouble Eng. Ne Speed Sensor Error
689 CA689
Contents of
Abnormality occurred in engine Ne speed sensor circuit.
trouble
Action of
Operates with signals of Bkup speed sensor.
controller
Problem that
Running engine stops (when Bkup speed sensor is also abnormal).
appears on
machine Stopped engine cannot be started (when Bkup speed sensor is also abnormal).
Related
information

Defective sensor power supply If code [238/CA238] is indicated, carry out troubleshooting for it
1
system first.
Disconnection in wiring har- Wiring harness between ENG1 (female) Resis-
Max. 1 z
ness (26) NE (female) (1) tance
2
(44) NE (female) (2) tance
Max. 1 z
(42) NE (female) (3) tance
Ground fault in wiring harness (26) NE (female) (1) and chassis ground tance 1 Mz
3
(44) NE (female) (2) and chassis ground tance 1 Mz
Possible causes Wiring harness between ENG1 (female) Resis- Min.
and standard (42) NE (female) (3) and chassis ground tance 1 Mz
value in normal
state
(26) NE (female) (1) and Resis- Min.
(44) NE (female) (2)
4
(With another wiring harness) (26) NE (female) (1) and Resis- Min.
(44) NE (female) (2) and Resis- Min.
Check Ne speed sensor directly for defective mount (defective
Defective mount of sensor or
5 clearance) or check rotation sensing part (crankshaft pulley)
defective rotation sensing part
directly for defect.
If causes 1 5 are not detected, engine Ne speed sensor may be
Defective engine Ne speed
6 defective. (Since trouble is in system, troubleshooting cannot be
sensor
carried out.)
12 95E-5 Series

and standard If causes 1 6 are not detected, engine controller may be defec-
value in normal 7 Defective engine controller tive. (Since trouble is in system, troubleshooting cannot be car-
state ried out.)
Circuit diagram related to engine Ne speed sensor
95E-5 Series 13
E-37 Code [731/CA731] Eng. Bkup Speed Sensor Phase Error 1

Trouble Eng. Bkup Speed Sensor Phase Error
731 CA731
Contents of
Engine Bkup speed sensor circuit detected abnormality in phase.
trouble
Action of
Controls with signals of engine Ne speed sensor.
controller
Problem that
Running engine stops (when Ne speed sensor is also abnormal).
appears on
machine Stopped engine cannot be started (when Ne speed sensor is also abnormal).
Related
information

Possible causes
Defective engine Ne speed Engine Ne speed sensor may be defective. Carry out trouble-
and standard 1
sensor system shooting for [689/CA698] (E-36).
value in normal
state Defective engine Bkup speed Engine Bkup speed sensor may be defective. Carry out trouble-
2
sensor system shooting for [778/CA778] (E-39).
14 95E-5 Series
E-38 Code [757/CA757] All Persistent Data Lost Error 1

Trouble All Persistent Data Lost Error
757 CA757
Contents of
All data in engine controller are lost.
trouble
Action of
None in particular.
controller
Problem that
machine
Related
information

and standard
state
95E-5 Series 15
E-39 Code [778/CA778] Eng. Bkup Speed Sensor Error 1

Trouble Eng. Bkup Speed Sensor Error
778 CA778
Contents of
Abnormality occurred in engine Bkup speed sensor circuit.
trouble
Action of
Operates with signals of Ne speed sensor.
controller
Problem that
Running engine stops (when Ne speed sensor is also abnormal).
appears on
machine Stopped engine cannot be started (when Ne speed sensor is also abnormal).
Related
information

1
Disconnection in wiring har- Wiring harness between ENG1 (female) Resis-
Max. 1 z
ness (36) CAM (female) (1) tance
2
(48) CAM (female) (2) tance
Max. 1 z
(37) CAM (female) (3) tance
Resis- Min.
(36) CAM (female) (1) and chassis
tance 1 Mz
ground
Possible causes Ground fault in wiring harness
3
and standard (Short circuit with GND circuit) Wiring harness between ENG1 (female) Resis- Min.
value in normal tance 1 Mz
ground
state
Resis- Min.
tance 1 Mz
ground
Resis- Min.
(36) CAM (female) (1) and between
tance 1 Mz
ENG1 (female) (48) CAM (female) (2)
4 Wiring harness between ENG1 (female)
(With another wiring harness) Resis- Min.
tance 1 Mz
Resis- Min.
tance 1 Mz
Check Bkup speed sensor directly for defective mount (defective
Defective mount of sensor or
5 clearance) or check rotation sensing part (in supply pump)
defective rotation sensing part
directly for defect.
16 95E-5 Series

If causes 1 5 are not detected, engine Bkup speed sensor may
Possible causes Defective engine Bkup speed
6 be defective. (Since trouble is in system, troubleshooting cannot
and standard sensor
be carried out.)
value in normal
state If causes 1 6 are not detected, engine controller may be defec-
7 Defective engine controller tive. (Since trouble is in system, troubleshooting cannot be car-
ried out.)
Circuit diagram related to engine Bkup speed sensor
95E-5 Series 17
E-40 Code [1633/CA1633] KOMNET Dtalink Timeout Error 1

Trouble KOMNET Dtalink Timeout Error
1633 CA1633
Contents of
Abnormality occurred in circuit of KOMNET communication with machine.
trouble
Action of
Operates in default mode or maintains condition when abnormality occurs.
controller
Problem that
appears on
machine
Related
information

Possible causes
and standard This fault is detected and indicated when KOMNET communica-
value in normal Carry out troubleshooting on tion with machine monitor or controller on the machine side is
1
state machine side abnormal. Accordingly, contents of troubleshooting depends on
machine model. See Shop manual for machine.
18 95E-5 Series
E-41 Code [2185/CA2185] Throttle Sens. Sup. Volt. High Error 1


Trouble Throttle Sens. Sup. Volt. High Error
2185 CA2185
Contents of
Signal voltage in throttle sensor power supply (5 V) circuit is abnormally high.
trouble
Problem that
machine
Related
information
95E-5 Series 19
Throttle sensor of fuel control dial type

Trouble Throttle Sens. Sup. Volt. High Error
2185 CA2185
Contents of
Signal voltage in throttle sensor power supply (5 V) circuit is abnormally high.
trouble
Action of Sets throttle angle with signal other than throttle sensor signal and continues operation (depending
controller on each model).
Problem that
appears on Depends on machine model.
machine
Related
information

Disconnect devices
Defective fuel control dial at right in order. If
1 error code disap-
(Internal trouble)
pears when a device Fuel control dial P20 connector
device has a defect
in it.
ness (Disconnection in wiring Wiring harness between CE2 (female) (27) Resis-
2 Max. 1 z
or defective contact in connec- P20 (female) (1) tance
Possible causes tor) Wiring harness between CE2 (female) (28) Resis-
Max. 1 z
and standard P20 (female) (3) tance
Ground fault in wiring harness Wiring harness between CE2 (female) (27) Resis- Min.
3
(Short circuit with GND circuit) P20 (female) (1) and chassis ground tance 1 Mz
4 Wiring harness between CE2 (female) (27)
(with another wiring harness) Resis- Min.
P20 (female) (1) and between CE2
tance 1 Mz
(female) (28) P20 (female) (3)
CE2 Voltage
Between (27) (28) 4.75 5.25 V
20 95E-5 Series
Circuit diagram related to throttle sensor of fuel control dial type (Case of PC128/138US-8)
95E-5 Series 21
E-42 Code [2186/CA2186] Throttle Sens. Sup. Volt. Low Error 1

Trouble Throttle Sens. Sup. Volt. Low Error
2186 CA2186
Contents of
Signal voltage in throttle sensor power supply (5 V) circuit is abnormally low.
trouble
Action of Sets throttle angle with signal other than throttle sensor signal and continues operation (depending
controller on each model).
Problem that
appears on Depends on machine model.
machine
Related
information

and standard
state
22 95E-5 Series
E-43 Code [2249/CA2249] Rail Press. Very Low Error 1

Trouble Rail Press. Very Low Error
2249 CA2249
Contents of
Supply pump does not feed fuel (level 2).
trouble
Action of
Limits common rail pressure.
controller
Problem that
machine
Related
information

and standard
state
95E-5 Series 23
E-44 Code [2311/CA2311] Abnormality in IMV solenoid 1

Trouble Abnormality in IMV solenoid
2311 CA2311
Contents of
Resistance in supply pump actuator is abnormally high or low.
trouble
Action of
None in particular.
controller
Problem that
appears Engine output drops.
on machine
Related
information

1 Defective related system If another failure code is indicated, carry out troubleshooting for it.
Defective supply pump PREG (Male) Resistance
2
actuator
Between (1) (2) Max. 1 z
Between (2) chassis ground Min. 1 Mz
Disconnection in wiring har- without turning starting switch ON.
ness
Possible Wiring harness between ENG1 (female) (10) Resis-
3 (Disconnection in wiring or Max. 1 z
causes and PREG (female) (2) tance
defective contact in connec-
standard value Wiring harness between ENG1 (female) (14) Resis-
tor) Max. 1 z
in normal state PREG (female) (1) tance
Ground fault in wiring harness without turning starting switch ON.
4
(Short circuit with GND circuit) Wiring harness between ENG1 (female) (14) Resis- Min.
PREG (female) (1) tance 1 Mz
5 Defective engine controller ENG1 (Female) Resistance
Between (4) (10) Max. 1 z
Between (14) chassis ground Min. 1 Mz
24 95E-5 Series
Circuit diagram related to supply pump actuator (metering unit)
95E-5 Series 25
E-45 Code [2555/CA2555] Grid Heater Relay Volt. Low Error 1

Trouble Grid Heater Relay Volt. Low Error
2555 CA2555
Contents of
There is disconnection in intake air heater relay.
trouble
Action of
None in particular.
controller
Problem that
appears on Engine does not start easily at low temperature.
machine
Related
information

and standard
state
26 95E-5 Series
E-46 Code [2556/CA2556] Grid Heater Relay Volt. High Error 1

Trouble Grid Heater Relay Volt. High Error
2556 CA2556
Contents of
There is short circuit in intake air heater relay.
trouble
Action of
None in particular.
controller
Problem that
appears on Engine does not start easily at low temperature.
machine
Related Condition for driving heater relay depends on machine.
information Different machine models may have different connector Nos.

Defective intake air heater ing without turning starting switch ON.
1
relay (Internal trouble) RHR (male) Resistance
Between (1) (2) 200 400 z
ness (Disconnection in wiring Wiring harness between CE02 (female) Resis-
2 Max. 1 z
or defective contact in connec- (44) RHR (female) (2) tance
tor) Wiring harness between CE02 (female) Resis-
Max. 1 z
(54) RHR (female) (1) tance
Possible causes a Prepare with starting switch OFF, then carry out troubleshoot-
and standard ing without turning starting switch ON.
value in normal
state Resis- Min.
Ground fault in wiring harness (44) RHR (female) (2) and chassis
3 tance 1 Mz
Resis- Min.
(54) RHR (female) (1) and chassis
tance 1 Mz
ground
CE02 Heater relay Voltage
4 Defective engine controller Under operating
Max. 1 V
condition
Between (44) (54)
Under stopping con-
20 30 V
dition
Note: The names and Nos. of the connectors shown above are examples.
28 95E-5 Series
Circuit diagram related to intake air heater
95E-5 Series 29
E-47 Code [(---)/B@BAZG] Eng. Oil press. Low Speed Derate 1

Trouble Eng. Oil press. Low Speed Derate
B@BAZG
Contents of
Engine oil pressure is below operating range.
trouble
Action of
Limits output and continues operation (Limits fuel injection rate and engine speed).
controller
Problem that
machine
Related
information

and standard This fault is indicated on only machine side when detected.
value in normal Carry out troubleshooting on
1 Accordingly, contents of troubleshooting depends on machine
state machine side
model. See Shop manual for machine.
E-48 Code [(---)/B@BAZG] Eng. Oil press. Torque Derate 1

Trouble Eng. Oil press. Torque Derate
B@BAZG
Contents of
Engine oil pressure is below operating range.
trouble
Action of
Limits output and continues operation (Limits fuel injection rate and engine speed).
controller
Problem that
machine
Related
information

state machine side
30 95E-5 Series
E-49 Code [(---)/B@BCNS] Eng. Overheat 1

Trouble Eng. Overheat
B@BCNS
Contents of
Engine coolant temperature is above operating range.
trouble
Action of
Limits output and continues operation.
controller
Problem that
machine
Related
information

state machine side
95E-5 Series 31
SEN02186-00
2006 KOMATSU
All Rights Reserved
32
SEN02184-00
Engine 1SHOP MANUAL
95E-5 Series
Troubleshooting of mechanical system
(S-mode)
Method of using troubleshooting charts .......................................................................................................... 4
S-1 Starting performance is poor .................................................................................................................... 8
S-2 Engine does not start ............................................................................................................................... 9
S-3 Engine does not pick up smoothly.......................................................................................................... 12
S-4 Engine stops during operations .............................................................................................................. 13
S-5 Engine does not rotate smoothly ............................................................................................................ 14
S-6 Engine lacks output (or lacks power) ..................................................................................................... 15
S-7 Exhaust smoke is black (incomplete combustion).................................................................................. 16
S-8 Oil consumption is excessive (or exhaust smoke is blue) ...................................................................... 17
S-9 Oil becomes contaminated quickly ......................................................................................................... 18
S-10 Fuel consumption is excessive............................................................................................................. 19
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) ................................................... 20
S-12 Oil pressure drops ................................................................................................................................ 21
S-13 Oil level rises (Entry of coolant or fuel)................................................................................................. 22
95E-5 Series 1
S-14 Coolant temperature becomes too high (overheating) ......................................................................... 23

S-15 Abnormal noise is made ....................................................................................................................... 24
S-16 Vibration is excessive ........................................................................................................................... 25
2 95E-5 Series
Method of using troubleshooting

charts 1
The troubleshooting chart consists of the ques-
tions, check items, causes, and troubleshoot-
ing blocks.
The questions and check items are used to pinpoint
high probability causes by simple inspection or
from phenomena without using troubleshooting
tools.
Next, troubleshooting tools or direct inspection are
applied to check the narrowed causes in order from
the most probable one to make final confirmation
according to the troubleshooting procedure.
[Questions]:
Items to be drawn from the user or operator.
They correspond to A and B in the chart on the
right.
The items in A are basic ones.
The items in B can be drawn from the user or
operator, depending on their level.
[Check items]:
Items to be simply checked by the serviceman
to narrow down causes.
They correspond to C in the chart on the right.
[Causes]:
Items to be narrowed from the questions and
check items.
The serviceman narrows down the probable
causes from A, B, and C.
[Troubleshooting]:
Items to finally verify whether the narrowed
down causes are undoubtedly the real causes
using the troubleshooting tools and direct
inspections.
4 95E-5 Series
Items listed in the [Questions] and [Check items] and related to the [Causes] are marked with E, Q, or w.
E : Causes to be referred to for questions and check items
Q : Causes related to questions and check items
w : Causes highly probable among ones marked with Q
a When narrowing the causes, apply the items marked with w before those marked with Q.
When narrowing the causes, do not apply the items marked with E. (If no items have other marks and
the causes cannot be narrowed, however, you may apply them.)
95E-5 Series 5
<Example of troubleshooting> Exhaust gas is black

Let us assume that [Clogged air cleaner] is taken to be the cause of black exhaust gas. 3 symptoms have
causal relationship with this problem: [Color of exhaust gas gradually became black], [Power was lost gradu-
ally], and [Air cleaner clogging caution lamp is flashing].
6 95E-5 Series
If we look from these 3 symptoms to find the causes, we find that there is a relationship with 5 causes. Let us
explain here the method of using this causal relationship to pinpoint the most probable cause.
95E-5 Series 7
S-1 Starting performance is poor 1

General causes why starting performance is poor Causes
q Defective electrical system
Leaking or clogged fuel piping, entry of air

Clogged air breather hole of fuel tank cap
Defective contact of valve and valve seat
Insufficient supply of fuel
Defective alternator (generator section)

q
Defective alternator (regulator section)

q Insufficient intake of air
Stuck, seized supply pump plunger
Defective intake air heater system

Improper selection of fuel
Defective or deteriorated battery

q
a The common rail fuel injection system (CRI) controls the
Clogged air cleaner element

fuel injection timing electrically. Accordingly, even if the
Worn piston ring, cylinder

starting operation is carried out, the engine may not start
until the crankshaft revolves 2 turns at maximum. This phe-
Clogged fuel filter
Defective injector
nomenon does not indicate a trouble, however.
Confirm recent repair history

Degree of use of machine Operated for long period E E E
Became worse gradually Q w w Q
Starting performance
Engine starts easily when warm w w
Questions
Non-specified fuel is being used Q Q Q

Replacement of filters has not been carried out according to Operation and
Maintenance Manual w w Q Q
Oil must be added more frequently w

When engine is preheated or when temperature is low, preheating monitor does not
w
indicate normally (if monitor is installed)
During operation, charge level monitor indicates abnormal charge (if monitor is installed) w w
Dust indicator is red (if indicator is installed) w
Air breather hole of fuel tank cap is clogged w
Fuel is leaking from fuel piping w Q
When priming pump is operated, it makes no reaction or it is heavy w Q
Starting motor cranks engine slowly w
If air bleeding plug of fuel filter is removed, fuel does not
While engine is cranked flow out w
with starting motor,
If spill hose from injector is disconnected, little fuel spills w
Check items
When exhaust manifold is touched immediately after starting engine, temperature of

w
some cylinders is low
Engine does not pick up smoothly and combustion is irregular Q Q w
There is hunting from engine (rotation is irregular) Q w Q
Blow-by gas is excessive w
Inspect air cleaner directly q

When compression pressure is measured, it is found to be low q q
When air is bled from fuel system, air comes out q
Inspect fuel filter directly q
Troubleshooting
Carry out troubleshooting according to No-pressure feed by supply pump (*1) in E-mode q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not q
change
When starting switch is turned to HEAT, intake air heater mount does not become warm q
Is voltage 20 30 V between alternator terminal B and terminal E with Yes q

engine at low idle? No q
When specific gravity of electrolyte and voltage of battery are measured, they are low q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Remedy
*1: Code [559/CA559] and code [2249/CA2249] in E-mode
8 95E-5 Series
S-2 Engine does not start 1

a) Engine does not turn Causes
General causes why engine does not turn
Defective connection of battery terminal
Defective starting motor (motor section)

q Seized parts inside engine
o See S-4 Engine stops during operations
Defective or deteriorated battery
Defective steering circuit wiring

q Defective electrical system
q Problem in drive devices on applicable machine side
Broken flywheel ring gear
Defective starting switch

o Carry out troubleshooting for devices on applicable machine
Defective battery relay
Defective safety relay

Questions
Degree of use of machine Operated for long period E E
Condition of horn when Horn does not sound Q Q w

starting switch is turned ON Horn volume is low w
Battery electrolyte is low w
Battery terminal is loose w
When starting switch is turned ON, there is no operating sound from battery relay Q w
When starting switch is turned to START, starting pinion does not move out Q Q w
Check items
Speed of rotation is low w

When starting switch is Makes grating noise w w
turned to START, starting
pinion moves out, but Soon disengages again w
Makes rattling noise and does not turn Q Q Q
Inspect flywheel ring gear directly q

Carry out troubleshooting

on applicable machine
There is not voltage (20 30 V) between battery relay terminal B q
and terminal E
Troubleshooting
When terminal B and terminal C of starting switch are connected,

q
engine starts
Turn starting switch OFF,
connect cord, and carry out When terminal B and terminal C at safety relay outlet are q
connected, engine starts
troubleshooting at ON
Even if terminal B and terminal C at safety relay outlet are
connected, engine does not start q
When terminal at safety switch and terminal B at starting motor are

q
connected, engine starts
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Remedy
95E-5 Series 9
b) Engine turns but no exhaust smoke comes out Causes

General causes why engine turns but no exhaust smoke comes
Defective operation of overflow valve (Does not close)

out
q Fuel is not being supplied
q Supply of fuel is extremely small

q Improper selection of fuel (particularly in winter)
Defective common rail pressure limiter

Seized, abnormally worn feed pump

Defective supply pump MPROP
Broken supply pump shaft
Insufficient fuel in tank
Defective fuel injector

Use of improper fuel
Clogged fuel filter

Questions
Exhaust smoke suddenly stopped coming out (when starting again) w Q w w E

Fuel other than specified one is used w
Non-specified fuel is being used w
Replacement of filters has not been carried out according to Operation and w E Q
Maintenance Manual
When fuel tank is inspected, it is found to be empty w
Rust and water are found when fuel tank is drained Q E E E
When fuel filter is removed, there is not fuel in it w w
Fuel is leaking from fuel piping w
Check items

While engine is cranked with flow out Q Q w Q
starting motor,
If spill hose from injector is disconnected, little fuel spills Q w w w Q

Inspect feed pump directly q
Troubleshooting
Carry out troubleshooting according to No-pressure feed by supply pump (*1) in E- q q

mode
Carry out troubleshooting according to Abnormality in supply pump IMV (*2) in E-
mode q
Inspect overflow valve directly q

Engine can be started in reduced cylinder mode q
Fuel flows out when pressure limiter return piping is disconnected q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Add
Remedy
*1: Code [559/CA559] and code [2249/CA2249] in E mode

*2: Code [271/CA271] and code [272/CA272] in E mode
10 95E-5 Series
c) Exhaust smoke comes out but engine does not start Causes
(fuel is being injected)
Worn dynamic valve system (Valve, rocker lever, etc.)
Defective coolant temperature sensor, wiring harness

General causes why exhaust smoke comes out but engine does
not start
Leaking or clogged fuel system, entry of air

q Lack of rotating force due to defective electrical system

q Insufficient supply of fuel
Defective intake air heater system

Improper selection of fuel
Clogged injector, defective spray

q
Defective, deteriorated battery

Clogging of fuel filter

Use of improper fuel
Suddenly failed to start w w Q
Questions
Non-specified fuel is being used Q Q

Replacement of filters has not been carried out according to Operation and
w w
Maintenance Manual
When engine is preheated or when temperature is low, preheating monitor does not w
indicate normally (if monitor is installed)
Air breather hole of fuel tank cap is clogged Q
Rust and water are found when fuel tank is drained w
When fuel filter is removed, there is not fuel in it w
Starting motor cranks engine slowly w
When engine is cranked, abnormal sound is generated around cylinder head w
Check items

While engine is cranked with flow out Q w
starting motor,
If spill hose from injector is disconnected, little fuel spills w
When exhaust manifold is touched immediately after starting engine, temperature of w

Inspect dynamic valve system directly q
When compression pressure is measured, it is found to be low q
Troubleshooting

Engine can be started in reduced cylinder mode q
Coolant temperature gauge does not indicate normally (if coolant temperature gauge is
installed) q
When starting switch is turned to HEAT, intake air heater mount does not become warm q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Remedy
95E-5 Series 11
S-3 Engine does not pick up smoothly 1

General causes why engine does not pick up smoothly Causes
Seized turbocharger, interference of turbocharger

q Defective condition of fuel injection

q Improper selection of fuel
q Controller is controlling in derate mode

(limiting injection rate (output) because of an error in electrical system)
Clogged injector, defective spray


Improper valve clearance

Degree of use of machine Operated for long period E E E E
Questions
Engine pick-up suddenly became worse w Q Q Q

Non-specified fuel is being used w w w
Replacement of filters has not been carried out according to Operation and Maintenance
w w
Manual
Rust and water are found when fuel tank is drained w
When exhaust manifold is touched immediately after starting engine, temperature of some Q w
cylinders is low
Blue under light load w
Color of exhaust gas is
w Q w w
Check items
Black
When engine is cranked, interference sound is generated around turbocharger w
High idle speed under no load is normal, but speed suddenly drops when load is applied Q w
There is hunting from engine (rotation is irregular) Q Q Q

Troubleshooting
Inspect valve clearance directly q

When turbocharger is rotated by hand, it is found to be heavy q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change q
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Clean
Clean
Clean
Remedy
12 95E-5 Series
S-4 Engine stops during operations 1

General causes why engine stops during opera- Causes
tions
Broken dynamic valve system (valve, rocker arm, etc.)
Broken auxiliary equipment (pump, compressor, etc.)

q Internal parts of engine seized
Defective engine controller power supply wiring

q There is overheating

q Problem in drive devices on applicable
machine side
Broken, seized piston, connecting rod

o Carry out troubleshooting for devices on
Broken, seized crankshaft bearing
Clogging feed pump gauze filter

applicable machine
Defective starting switch wiring

Leaking, clogged fuel piping
Broken, seized feed pump

Broken supply pump shaft
Defective hydraulic pump

Broken, seized gear train

Abnormal noise was heard and engine
stopped suddenly w w w w Q w Q w w
Condition when engine w Q Q
Questions
Engine overheated and stopped

stopped
Engine stopped slowly w Q Q Q Q
There was hunting and engine stopped w Q Q Q Q Q Q
Non-specified fuel is being used Q Q Q Q
Replacement of filters has not been carried out according to Operation
w w
and Maintenance Manual
Fuel level monitor indicates low level w
Rust and water are found when fuel tank is drained w w
Metal particles are found when oil pan is drained w w Q Q
Check items
Does not turn at all w w

When engine is cranked by Turns in opposite direction w
hand Moves by amount of gear backlash w w
Supply pump shaft does not turn w
Engine turns, but stops when load is applied to machine w

Inspect piston, connecting rod directly q
Inspect crankshaft bearing directly q
Inspect gear train directly q

Troubleshooting

Inspect feed pump gauge filter directly q
Inspect feed pump directly q
Carry out troubleshooting according to No-pressure feed by supply
pump (*1) in E-mode q q
Engine rotates when pump auxiliary equipment (pump, compressor,
q
etc.) is removed
Check controller power supply wiring q
Check starting switch wiring q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Clean
Clean
Add
Remedy

95E-5 Series 13
S-5 Engine does not rotate smoothly 1

General causes why engine does not rotate smoothly Causes
q Air in fuel system
Clogged injector, defective spray (dirt in injector)

Defective speed sensor (Error at degree that it is not indicated)
Defective Bkup speed sensor, wiring harness

q
Defective Ne speed sensor, wiring harness


Degree of use of machine Operated for long period E
Occurs at a certain speed range Q Q
Questions
Occurs at low idle Q Q Q Q Q

Hunting
Occurs even when speed is raised Q Q Q
Occurs on slopes w
Replacement of filters has not been carried out according to Operation and Maintenance Manual w
Check items
Rust and water are found when fuel tank is drained Q


Troubleshooting

Carry out troubleshooting according to Abnormality in Ne speed sensor (*1) in E-mode q
Carry out troubleshooting according to Abnormality in Bkup speed sensor (*2) in E-mode q
Replace
Replace
Replace
Replace
Replace
Clean
Add
Remedy
*1: Code [689/CA689] in E-mode

*2: Code [778/CA778] in E-mode
14 95E-5 Series
S-6 Engine lacks output (or lacks power) 1

General causes why engine lacks output Causes
Clogged injector, defective spray (dirt in injector)
Defective boost pressure sensor, wiring harness

Insufficient supply of fuel
Defective installation of boost pressure sensor

q
Defective drive of injector (signal, solenoid)



Air leakage from air intake piping

o See S-14 Coolant temperature becomes too
Leaking, clogged fuel piping

high (Overheating)

Clogged fuel spill piping


(limiting injection rate (output) because of an
error in electrical system)
(air leakage)
Suddenly Q w Q Q Q Q
Questions
Power was lost

Gradually Q Q Q Q Q Q
Non-specified fuel is being used Q Q Q
Replacement of filters has not been carried out according to Operation and w w
Maintenance Manual
Oil must be added more frequently Q Q
Dust indicator is red (if indicator is installed) w w
Output becomes insufficient after short stop of operation w
Black w w
w w
w
Check items
When engine is cranked, interference sound is generated around turbocharger

High idle speed is too high Q
High idle speed under no load is normal, but speed suddenly drops when load is applied Q w Q Q
Engine does not pick up smoothly and combustion is irregular w w Q Q w
There is hunting from engine (rotation is irregular) Q Q Q Q Q
Blow-by gas is excessive w w

Inspect air intake piping directly q
When boost pressure is measured, it is found to be low q q q
Troubleshooting
Inspect fuel piping q

Inspect spill port check valve directly q
Carry out troubleshooting according to No-pressure feed by supply pump (*1) in E-
q
mode
When a cylinder is cut out for reduced cylinder mode operation, engine speed does
q q
not change
Inspect charge pressure sensor mount directly q
Carry out troubleshooting according to Abnormality in charge pressure sensor (*2)
in E-mode q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Adjust
Clean
Clean
Remedy

95E-5 Series 15
S-7 Exhaust smoke is black (incomplete combustion) 1

General causes why exhaust smoke is black Causes
Leakage of air between turbocharger and cylinder head



o See S-14 Coolant temperature becomes too high
(Overheating)

Improper fuel injection pressure

(limiting injection rate (output) because of an error in

Crushed, clogged muffler

electrical system)
Abnormally worn injector

Improper injection timing
Clogged, seized injector
Suddenly became black w w Q Q Q
Color of exhaust gas is Gradually became black w Q Q
Questions

Suddenly w Q Q Q
Power was lost
Gradually Q Q Q Q
Muffler is crushed w
Air leaks between turbocharger and cylinder head, clamp is loosened w
Engine is operated in low-temperature mode at normal temperature Q Q Q
When exhaust manifold is touched immediately after starting engine, temperature of some Q w
cylinders is low
Check items

Torque converter stall speed or pump relief speed is high (Fuel is injected excessively) Q
Exhaust noise is abnormal Q w Q
Engine does not pick up smoothly and combustion is irregular Q Q Q Q Q w
If spill hose from injector is disconnected, abnormally much fuel spills w

When turbocharger is rotated by hand, it is fount to be heavy q
Troubleshooting

When muffler is removed, exhaust sound improves q
Carry out troubleshooting according to No-pressure feed by supply pump (*1) in E-mode q q
Carry out troubleshooting according to Abnormality in coolant temperature sensor (*2) in E-
mode q
Confirm with INSITE or with monitoring function on applicable machine side q q

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Clean
Remedy

16 95E-5 Series
S-8 Oil consumption is excessive (or exhaust smoke is blue) 1

General causes why oil consumption is excessive Causes
q Abnormal consumption of oil
Turbocharger
Oil leakage from oil pan, cylinder head, etc.

Worn, damaged valve (stem, guide, seal)
q Long-time operation of engine at low idle or high idle
(Do not run engine at idle for more than 20 minutes
Dust sucked in from intake system

continuously)
Clogged breather, breather hose

q External leakage of oil
Oil leakage from oil drain plug

Worn, damaged rear oil seal
q Wear of pats in lubrication system
Oil leakage from oil cooler
Oil leakage from oil piping

Worn seal at turbine end
Worn seal at blower end
Oil leakage from oil filter

Broken piston ring
Broken oil cooler

Questions
Oil consumption suddenly increased w Q

Oil must be added more frequently w Q
Oil becomes contaminated quickly Q Q w
Outside of engine is dirty with oil w w w w w
There are loose piping clamps in intake system w
Inside of turbocharger intake outlet pipe is dirty with oil w
Inside of turbocharger exhaust outlet pipe is dirty with oil Q w
Check items
There is oil in coolant w

Oil level in clutch chamber or damper chamber is high w
Exhaust smoke is blue under light load w w
Excessive Q Q w w
Amount of blow-by gas
None w
When intake manifold is removed, dust is found inside q

When intake manifold is removed, inside is found to be dirty abnormally q
Troubleshooting
Excessive play of turbocharger shaft q q

Check breather and breather hose directly q
Inspect rear oil seal directly q
Pressure-tightness test of oil cooler shows there is leakage q q
There is external leakage of oil from engine q q q q
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
95E-5 Series 17
S-9 Oil becomes contaminated quickly 1

General causes why oil becomes contaminated quickly Causes
q Entry of exhaust gas into oil due to internal wear
Clogged turbocharger lubrication drain tube

Defective seal at turbocharger turbine end
q Clogging of lubrication passage
q Use of improper fuel
q Use of improper oil
Clogged breather, breather hose

q Operation under excessive load
Defective oil filter safety valve

Worn valve, valve guide
Exhaust smoke is bad

Clogged oil cooler
Clogged oil filter
Questions

Metal particles are found when oil filter is drained Q Q w
Inside of exhaust pipe is dirty with oil w
Engine oil temperature rises quickly w
Check items

Black w
Excessive Q Q w Q
Amount of blow-by gas
None w
Excessive play of turbocharger shaft q

Troubleshooting
Check breather and breather hose directly q
See S-7
Inspect oil cooler directly q
Inspect oil filter directly q
Spring of oil filter safety valve is hitched or broken q
Inspect turbocharger lubrication drain tube directly q
Replace
Replace
Replace
Replace
Replace
Replace
Clean
Clean
Remedy
18 95E-5 Series
S-10 Fuel consumption is excessive 1

General causes why fuel consumption is excessive Causes
q Leakage of fuel

q Defective condition of fuel injection (fuel pressure, injection timing)
q Excessive injection of fuel
Fuel leakage from fuel filter, piping, etc.
Defective common rail pressure

Fuel leakage inside head cover
Defective supply pump plunger
Defective operation of injector

Defective feed pump oil seal
Defective spray by injector
Improper injection timing

Questions
More than for other machines of same model Q Q Q Q

Condition of fuel
consumption Gradually increased Q Q
Suddenly increased Q Q
There is external leakage of fuel from engine w
Combustion is irregular w
Engine oil level rises and oil smells of diesel fuel w w
When exhaust manifold is touched immediately after starting engine, temperature of some w
cylinders is low
Check items
Low idle speed is high Q

Torque converter stall speed or pump relief speed is high Q
Black Q Q Q Q
White Q
Remove head cover and inspect directly q

Inspect feed pump oil seal directly q
Troubleshooting
If spill hose from injector is disconnected, much fuel spills q
Carry out troubleshooting according to Abnormality in coolant temperature sensor (*2) in E-mode q
Confirm with INSITE or with monitoring function on applicable machine side q q
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy

95E-5 Series 19
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)1
General causes why oil is in coolant Causes
q Internal leakage in lubrication system
Broken cylinder head, head gasket
power train oil cooler on applicable

q Internal leakage in cooling system
Broken oil cooler core, O-ring
Broken hydraulic oil cooler or

Cracks inside cylinder block
Holes caused by pitting
machine side
Questions
Suddenly rose Q Q Q
Oil level
Gradually rose Q Q
Hard water is being used as coolant Q Q
Oil level has risen and oil is milky Q Q w
There are excessive air bubbles in radiator, coolant spurts back w
Check items
Hydraulic oil or power train oil on applicable machine side is milky w

When hydraulic oil or power train oil is drained, water is found w
Pressure-tightness test of cylinder head shows there is leakage q Carry out

shooting
Trouble-
troubleshooting
Inspect cylinder block, liner directly q q on applicable
Pressure-tightness test of oil cooler shows there is leakage q machine
Replace
Replace
Replace
Replace
Remedy
20 95E-5 Series
S-12 Oil pressure drops 1

General causes why oil pressure drops Causes
q Leakage, clogging, wear or lubrication system
Leaking, crushed, clogged hydraulic piping

Defective oil level sensor, wiring harness
q Defective oil pressure control
q Improper selection of fuel (improper viscosity)
q Deterioration of oil due to overheating
Clogged, broken pipe in oil pan

Clogged strainer in oil pan
Defective regulator valve

Worn journal of bearing
Lack of oil in oil pan
Defective oil pump

Coolant, fuel in oil
Clogged oil filter

Questions
Oil pressure monitor indicates low oil pressure (if monitor is installed) Q w
Non-specified oil is being used Q Q
Replacement of filters has not been carried out according to Operation and Maintenance
Manual w
Indicates pressure drop at low idle w
Oil pressure monitor Indicates pressure drop at low, high idle Q w w w Q

(if installed) Indicates pressure drop on slopes w
Sometimes indicates pressure drop w Q
Oil level monitor indicates oil level drop (if monitor is installed) w w
Oil level in oil pan is low w
External hydraulic piping is leaking, crushed w
Check items
Oil is milky or smells of diesel oil w

Metal particles are found when oil pan is drained w
Metal particles are found when oil filter is drained w Q
Metal particles are found in oil filter q

Troubleshooting
Inspect oil pan strainer, pipe directly q q

See S-13
Oil pump rotation is heavy, there is play in oil pump q

Valve and spring of regulator valve are fatigued, damaged q
Inspect oil filter directly q
If oil level sensor is replaced, oil level monitor indicates normally q
Replace
Replace
Replace
Replace
Correct
Adjust
Clean
Clean
Add
Remedy
95E-5 Series 21
S-13 Oil level rises (Entry of coolant or fuel) 1

General causes why oil level rises Causes
q Coolant in oil (milky)
Defective seal of auxiliary equipment (pump, compressor)

q Fuel in oil (smells diluted diesel fuel)
a If oil is in coolant, carry out troubleshooting for S-11 Oil is in coolant
Broken oil cooler core, O-ring

Worn, damaged rear oil seal
Cracks inside cylinder block
Defects in supply pump

Broken injector, O-ring
Questions

Fuel must be added more frequently w w
Coolant must be added more frequently Q Q
There is oil in coolant Q Q Q Q w
Oil smells of diesel fuel w w
Oil is milky Q Q
When engine is started, drops of water come from muffler Q
When radiator cap is removed and engine is run at low idle, an abnormal number of bubbles appears, w Q
Check items
or coolant spurts back

Exhaust smoke is white Q
Oil level in clutch chamber or damper chamber is low w
Oil level in hydraulic tank of machine is low w

Remove injector and inspect O-ring. q
Troubleshooting
Inspect cylinder block, liner directly q q

Inspect rear oil seal directly q
Pressure-tightness test of oil cooler shows there is leakage q
Remove and inspect supply pump directly q
Inspect seal of auxiliary equipment directly q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Remedy
22 95E-5 Series
S-14 Coolant temperature becomes too high (overheating) 1

General causes why coolant temperature becomes too high Causes
q Lack of cooling air (deformation, damage of fan)
Defective radiator cap (pressure valve)
Rise in power train oil temperature on

Defective coolant temperature gauge
q Drop in heat dissipation efficiency
Defective operation of thermostat

Problem in coolant circulation system
Slipping fan belt, worn fan pulley

q
Clogged, crushed radiator fins

q Rise in oil temperature in power train
o Carry out troubleshooting on applicable machine
Clogged, broken oil cooler
applicable machine side

Clogged radiator core

Broken water pump
Lack of coolant
Questions
Sudden overheated Q w Q
Condition overheating
Always tends to overheat Q w w Q
Coolant temperature gauge Rises quickly Q w

(if installed) Does not go down from red range w
Radiator coolant level monitor indicates drop of coolant level (if monitor is installed) w
Engine oil level has risen, oil is milky w Q
Fan belt tension is low w
When fan pulley is turned, it has play w
Milky oil is floating on coolant w
There are excessive air bubbles in radiator, coolant spurts back w
When light bulb is held behind radiator core, no light passes through w
Check items
Radiator shroud, inside of underguard on applicable machine side are clogged with w w
dirt or mud
Coolant is leaking because of cracks in hose or loose clamps w
Coolant flows out from radiator overflow hose w
Fan belt whines under sudden acceleration w
Power train oil temperature enters red range faster than engine coolant
temperature (if oil temperature gauge and coolant temperature gauge are w
installed)

Inspect cylinder liner directly q
Inspect oil cooler directly q

Temperature difference between upper and lower tanks of radiator is large q

Troubleshooting
When operation of thermostat is carried out, it does not open at cracking

temperature q
Temperature difference between upper and lower tanks of radiator is slight q

Inspect radiator core directly q
When operation of radiator cap is carried out, its cracking pressure is low q
Inspect fan belt, pulley directly q
When coolant temperature is measured, it is found to be normal q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Add
Remedy
95E-5 Series 23
S-15 Abnormal noise is made 1

General causes why abnormal noise is made Causes
q Abnormality due to defective parts
Deformed cooling fan, loose fan belt, interference of fan belt

Abnormal combustion
Defective inside of muffler (dividing board out of position)

q
Leakage of air between turbocharger and cylinder head

q Air sucked in from intake system
Improper fuel injection timing (abnormality in coolant

a Judge if the noise is an internal noise or an external
Broken dynamic valve system (valve, rocker lever)

Interference of turbocharger, seized turbocharger
temperature sensor, boost temperature sensor)

noise before starting troubleshooting.
a The engine is operated in the low-temperature mode
while it is not warmed up sufficiently. Accordingly, the
Excessive wear of piston ring, cylinder

engine sound becomes a little larger. This does not indi-
cate abnormality, however.
a When the engine is accelerated, it is operated in the
Improper gear train backlash

acceleration mode and its sound becomes a little larger
Removed, seized bushing

Clogged, seized injector

for up to about 3 seconds. This does not indicate abnor-
Dirt caught in injector

mality, however.

Degree of use of machine Operated for long period E
Questions
Gradually occurred Q Q
Condition of abnormal noise
Suddenly occurred Q Q Q
Non-specified fuel is being used Q
Metal particles are found when oil filter is drained w w
Air leaks between turbocharger and cylinder head w
When engine is cranked, abnormal sound is generated around cylinder head w w
When engine is cranked, beat noise is generated around muffler w
Check items
w Q
Black Q w Q
Engine does not pick up smoothly and combustion is irregular w
Abnormal noise is loud when engine is accelerated Q Q Q Q
When turbocharger is rotated by hand, it is found to be heavy q

When muffler is removed, abnormal noise disappears q
Troubleshooting

Inspect gear train directly q q
Inspect fan and fan belt directly q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does q q
not change
Abnormal noise is heard only when engine is started q
Confirm with INSITE or with monitoring function on applicable machine side q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Remedy
24 95E-5 Series
S-16 Vibration is excessive 1

General causes why vibration is excessive Causes
q Defective parts (abnormal wear, breakage)
Misalignment between engine and devices on applicable machine side

q Misalignment between engine and chassis
Improper fuel injection timing (abnormality in coolant temperature

Abnormal combustion
Broken output shaft, parts in damper on applicable machine side

q
a If abnormal noise is made and vibration is excessive, carry out trou-
bleshooting for S-15 Abnormal noise is made, too.
Stuck dynamic valve system (valve, rocker lever)
Loose engine mounting bolts, broken cushions

Worn main bearing, connecting rod bearing
sensor, boost temperature sensor)

Improper gear train backlash
Worn camshaft bushing
Questions
Suddenly increased Q Q
Condition of vibration
Gradually increased Q Q Q
Non-specified oil is being used Q Q
Metal particles are found when oil filter is drained w w
Metal particles are found when oil pan is drained w w
Oil pressure is low at low idle Q Q
Check items
Vibration occurs at mid-range speed Q Q

Vibration follows engine speed Q Q Q Q
Exhaust smoke is black w Q

Inspect main bearing and connecting rod bearing directly q
Troubleshooting
Inspect gear train directly q

Inspect camshaft bushing directly q
Confirm with INSITE or with monitoring function on applicable machine side q
Inspect engine mounting bolts and cushions directly q
When alignment is checked, radial runout or facial runout is detected q
Inspect output shaft or inside of damper directly q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Adjust
Remedy
95E-5 Series 25
KOMATSU 95E-5 Series Diesel engine
2006 KOMATSU
All Rights Reserved
26

Shop Manual 95e-5 Series

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Shop Manual 95e-5 Series

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SEN01966-00

ENGINE 95E -5 SERIES

ENGINE 1SHOP MANUAL

00 Index and foreword 1

Composition of shop manual................................................................................................................ 2

Composition of shop manual 1

Section Title Form Number

Shop Manual, contents binder, binder label and tabs SEN01966-00

00 Index and foreword SEN02120-00

10 Structure, function and maintenance standard SEN02125-00

20 Standard value table SEN02128-00

30 Testing and adjusting SEN02130-00

Foreword and general information SEN02122-00

10 Structure, function and maintenance standard

Fuel injection nozzle ................................................................................................................ 12

20 Standard value table

30 Testing and adjusting

KOMATSU 95E-5 Series engine

Form No. SEN02121-00

ENGINE 1SHOP MANUAL

00 Index and foreword 1

Safety notice 1 (Rev. 2006/09)

1. General precautions 7) If welding repairs are needed, always

4. Precautions for sling work and making

8. Precautions for disconnecting and con-

a Example of O-ring (Fitted to every joint of

a For tightening torque, see the precautions for

How to read the shop manual 1

1. Composition of shop manual

00. Index and foreword

10. Structure, function and maintenance standard

20. Standard value table

30. Testing and adjusting

50. Disassembly and assembly

2. Revision and distribution

q Revised edition mark

Symbol Item Remarks

k Safety Special safety precautions are necessary when performing work.

Special technical precautions or other precautions for preserving stan-

2 Coat Places to be coated with adhesives, etc. during assembly.

Explanation of terms for maintenance standard 1

1. Standard size and tolerance

a The tolerance may be indicated in the text

q Usually, the size of a hole and the size of

2. Standard clearance and standard value 5. Clearance limit

4. Repair limit and allowable value

Handling electric equipment and hydraulic component 1

Points to remember when handling electric

2. Main failures occurring in wiring harness

2) Defective crimping or soldering of connec-

4) High-pressure water entering connector

5) Oil or dirt stuck to connector

3. Removing, installing, and drying connec-

2] When removing from clips

q When removing a connector from a

3] Action to take after removing connec-

4) Drying wiring harness

5. Points to remember when troubleshooting

Points to remember when handling hydraulic equipment

1. Be careful of the operating environment.

2. Disassembly and maintenance work in the

4. Do not let any dirt or dust get in during

5. Change hydraulic oil when the temperature

Connectors newly used for Tier 3 engines