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


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 accordingly. Section Title

Form Number

Shop Manual, contents binder, binder label and tabs

SEN01966-00

00 Index and foreword Index Foreword and general information

SEN02120-00 SEN02121-00 SEN02122-00

01 Specification Specification and technical data

SEN02123-00 SEN02124-00

10 Structure, function and maintenance standard Structure, function and maintenance standard, Part 1 Structure, function and maintenance standard, Part 2

SEN02125-00 SEN02126-00 SEN02127-00

20 Standard value table Standard service value table

SEN02128-00 SEN02129-00

30 Testing and adjusting Testing and adjusting

SEN02130-00 SEN02182-00

40 Troubleshooting General information on troubleshooting Troubleshooting of electrical system (E-mode), Part 1 Troubleshooting of electrical system (E-mode), Part 2 Troubleshooting of mechanical system (S-mode)

SEN02131-00 SEN02183-00 SEN02185-00 SEN02186-00 SEN02184-00

2

95E-5 Series


SEN02121-00

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 Structure, function and maintenance standard, Part 1 SEN02126-00 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 Structure, function and maintenance standard, Part 2 SEN02127-00 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

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SEN02121-00


Fuel injection nozzle ................................................................................................................ Fuel filter .................................................................................................................................. Common rail ............................................................................................................................ Various sensor ......................................................................................................................... Cooling system............................................................................................................................ Cooling system diagram .......................................................................................................... Water pump ............................................................................................................................. Cooling fan drive and thermostat............................................................................................. Electrical equipment .................................................................................................................... Starting and charging system electrical circuit diagram........................................................... Alternator ................................................................................................................................. Starting motor .......................................................................................................................... Starting aid............................................................................................................................... Engine controller......................................................................................................................

12 13 14 16 18 18 19 22 26 26 27 29 30 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 Troubleshooting of electrical system (E-mode), Part 1 SEN02185-00 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

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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-20 Code [324/CA324] Injector #3 (L/B #3) System Open/Short Error ..................................... 36 E-21 Code [331/CA331] Injector #2 (L/B #2) System Open/Short Error ..................................... 38 E-22 Code [332/CA332] Injector #4 (L/B #4) System Open/Short Error ..................................... 40 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 Troubleshooting of electrical system (E-mode), Part 2 SEN02186-00 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

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SEN02121-00

KOMATSU 95E-5 Series engine Form No. SEN02121-00

© 2006 KOMATSU All Rights Reserved Printed in Japan 12-06 (01)

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SEN02122-00

ENGINE 1SHOP MANUAL

95E-5 Series


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

SEN02122-00

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 situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation. 1.

2

General precautions k Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully before operating the machine. 1) Before carrying out any greasing or repairs, read all the safety plates stuck to the machine. For the locations of the safety plates and detailed explanation of precautions, see the Operation and Maintenance Manual. 2) Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt, water, or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working. 3) When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. q Always wear safety glasses when hitting parts with a hammer. q Always wear safety glasses when grinding parts with a grinder, etc. 4) When carrying out any operation with 2 or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR warning signs in the operator's compartment. 5) Only qualified workers must carry out work and operation which require license or qualification. 6) Keep all tools in good condition, learn the correct way to use them, and use the proper ones of them. Before starting work, thoroughly check the tools, machine, forklift, service car, etc.

7)

8)

If welding repairs are needed, always have a trained and experienced welder carry out the work. When carrying out w elding work, alw ays wear welding gloves, apron, shielding goggles, cap and other clothes suited for welding work. Before starting work, warm up your body thoroughly to start work under good condition.

Safety points 1 Good arrangement 2 Correct work clothes 3 Following work standard 4 Making and checking signs 5

Prohibition of operation and handling by unlicensed workers

6 Safety check before starting work 7

Wearing protective goggles (for cleaning or grinding work)

8

Wearing shielding goggles and protectors (for welding work)

9 Good physical condition and preparation 10

2.

Precautions against work which you are not used to or you are used to too much

Preparations for work 1) Before adding oil or making any repairs, park the machine on hard and level ground, and apply the parking brake and block the wheels or tracks to prevent the machine from moving. 2) Before starting work, lower the work equipment (blade, ripper, bucket, etc.) to the ground. If this is not possible, insert the lock pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them.

95E-5 Series


3) 4)

3.

When disassembling or assembling, support the machine with blocks, jacks, or stands before starting work. Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the 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 machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.

Precautions during work 1) Before disconnecting or removing components of the oil, water, or air circuits, first release the pressure completely from the circuit. When removing the oil filler cap, a drain plug, or an oil pressure pickup plug, loosen it slowly to prevent the oil from spurting out. 2) The coolant and oil in the circuits are hot when the engine is stopped, so be careful not to get scalded. Wait for the oil and coolant to cool before carrying out any work on the oil or water circuits. 3) Before starting work, stop the engine. When working on or around a rotating part, in particular, stop the engine. When checking the machine without stopping the engine (measuring oil pressure, revolving speed, temperature, etc.), take extreme care not to get rolled or caught in rotating parts or moving parts. 4) Before starting work, remove the leads from the battery. Always remove the lead from the negative (–) terminal first. 5) When raising a heavy component (heavier than 25 kg), use a hoist or crane. Before starting work, check that the slings (wire ropes, chains, and hooks) are free from damage. Always use slings which have ample capacity and install them to proper places. Operate the hoist or crane slowly to prevent the component from hitting any other part. Do not work with any part still 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 wiring. Damaged wiring may cause electrical fires.

95E-5 Series

SEN02122-00

8)

9) 10)

11)

12)

13) 14) 15)

16)

When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips onto the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip and can even start fires. As a general rule, do not use gasoline to wash parts. Do not use it to clean electrical parts, in particular. Be sure to assemble all parts again in their original places. Replace any damaged parts and parts which must not be reused with new parts. When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is operated. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits. In addition, check 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 installed. When assembling or installing parts, always tighten them to the specified torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly. When aligning 2 holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. When measuring hydraulic pressure, check that the measuring tools are correctly assembled. Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates suddenly, so never let anyone stand at either end of the track. If the engine is operated for a long time in a place which is not ventilated well, you may suffer from gas poisoning. Accordingly, open the windows and doors to ventilate well.

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SEN02122-00

4.

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. 3) Keep putting on gloves during sling work. (Put on leather gloves, if available.) 4) Measure the weight of the load by the eye and check its center of gravity. 5) Use proper sling according to the weight of the load and method of slinging. If too thick wire ropes are used to sling a light load, the load may slip and fall. 6) Do not sling a load with 1 wire rope alone. If it is slung so, it may rotate and may slip out of the rope. Install 2 or more wire ropes symmetrically. k Slinging with 1 rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding 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 forming 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 allowable 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 sling a load vertically, up to 19.6 kN {2,000 kg} of total weight can be suspended. This weight is reduced to 9.8 kN {1,000 kg} when the 2 ropes make a hanging angle of 120°. If the 2 ropes sling a 19.6 kN {2,000 kg} load at a lifting angle of 150°, each of them is subjected to a force as large as 39.2 kN {4,000 kg}.


8)

When installing wire ropes to an angular load, apply pads to protect the wire ropes. If the load is slippery, apply proper material to prevent the wire rope from slipping. 9) Use the specified eyebolts and fix wire ropes, chains, etc. to them with shackles, etc. 10) Apply wire ropes to the middle portion of the hook. q Slinging near the tip of the hook may cause the rope to slip off the hook during hoisting. The hook has the maximum strength at the middle portion.

11) Do not use twisted or kinked wire ropes. 12) When lifting up a load, observe the following. q Wind in the crane slowly until wire ropes are stretched. When settling the wire ropes with the hand, do not grasp them but press them from above. If you grasp them, your fingers may be caught. q After the wire ropes are stretched, stop the crane and check the condition of the slung load, wire ropes, and pads.

95E-5 Series


If the load is unstable or the wire rope or chains are twisted, lower the load and lift it up again. q Do not lift up the load slantingly. 13) When lifting down a load, observe the following. q When lifting down a load, stop it temporarily at 30 cm above the floor, and then lower it slowly. q Check that the load is stable, and then remove the sling. q Remove kinks and dirt from the wire ropes and chains used for the sling work, and put them in the specified place.

SEN02122-00

13) If the hoist stops because of a power failure, turn the power switch OFF. When turning on a switch which was turned OFF by the electric shock prevention earth leakage breaker, check that the devices related to that switch are not in operation state. 14) If you find an obstacle around the hoist, stop the operation. 15) After finishing the work, stop the hoist at the specified position and raise the hook to at least 2 m above the floor. Do not leave the sling installed to the hook.

q

5.

6.

Precautions for using mobile crane a Read the Operation and Maintenance Manual of the crane carefully in advance and operate the crane safely. Precautions for using overhead hoist crane k When raising a heavy part (heavier than 25 kg), use a hoist, etc. In Disassembly and assembly, the weight of a part heavier than 25 kg is indicated after the mark of 4. 1) Before starting work, inspect the wire ropes, brake, clutch, controller, rails, over wind stop device, electric shock prevention earth leakage breaker, crane collision prevention device, and power application warning lamp, and check safety. 2) Observe the signs for sling work. 3) Operate the hoist at a safe place. 4) Check the direction indicator plates (east, west, south, and north) and the directions of the control buttons without fail. 5) Do not sling a load slantingly. Do not move the crane while the slung load is swinging. 6) Do not raise or lower a load while the 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 immediately in an emergency.

95E-5 Series

7.

Selecting wire ropes 1) Select adequate ropes depending on the weight of parts to be hoisted, referring to the table below.

Wire ropes (Standard “Z” twist ropes without galvanizing) (JIS G3525, No. 6, Type 6X37-A) Nominal Allowable load diameter of rope mm kN ton 10 8.8 0.9 12 12.7 1.3 14 17.3 1.7 16 22.6 2.3 18 28.6 2.9 20 35.3 3.6 25 55.3 5.6 30 79.6 8.1 40 141.6 14.4 50 221.6 22.6 60 318.3 32.4

a

The allowable load is one-sixth of the breaking strength of the rope used (Safety coefficient: 6).

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SEN02122-00

8.

Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit 1) Disconnection k k

2)

Collect the air conditioner refrigerant gas (R134a). 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. Connection 1] When installing the air conditioner circuit 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 damaged or deteriorated. 4] When connecting the refrigerant piping, apply compressor oil for refrigerant (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 q q q

1.

SEN02122-00

1

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. Materials and specifications are subject to change without notice. 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. 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 disassembly 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.

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3.

4.


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.

Symbols Important safety and quality portions are marked with the following symbols so that the shop manual will be used practically. Symbol

Item

k

Safety

a

Caution

Special technical precautions or other precautions for preserving standards are necessary when performing work.

4

Weight

Weight of parts of component or parts. Caution necessary when selecting hoisting wire, or when working posture is important, etc.

3

Tightening torque

2

Coat

5

Oil, coolant

6

Drain

Remarks Special safety precautions are necessary when performing work.

Places that require special attention for tightening torque during assembly. Places to be coated with adhesives, etc. during assembly. Places where oil, etc. must be added, and capacity. 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, conventionally used Gravitational System of units is indicated in parentheses { }.

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SEN02122-00

Explanation of terms for maintenance standard

1

The maintenance standard values necessary for judgment of products and parts are described by the following 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 temporary standard size is set and an allowable difference from that size is indicated. q The above size set temporarily is called the “standard size” and the range of difference 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 120

Tolerance –0.022 –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 indicated by the same standard size and different tolerances of the hole and shaft. The tightness of fit is decided by the tolerance. Indication of size of rotating shaft and hole and relationship drawing of them

q

Example: Standard size 60

95E-5 Series

Tolerance Shaft Hole –0.030 +0.046 –0.076 +0

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SEN02122-00

2.

Standard clearance and standard value q The clearance made when new parts are assembled is called the “standard clearance“, which is indicated by the range from the minimum clearance to the maximum clearance. q When some parts are repaired, the clearance is generally adjusted to the standard clearance. q A value of performance and function of new products or equivalent is called the “standard value“, which is indicated by a range or a target value. q When some parts are repaired, the value of performance/function is set to the standard value.

3.

Standard interference q When the diameter of a hole of a part shown in the given standard size and tolerance 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 product 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 various tests or experiences in most cases, however, it must be judged after considering the operating condition and customer's requirement.

10


5.

Clearance limit Parts can be used until the clearance between them is increased to a certain limit. The limit at which those parts cannot be used is called the “clearance limit”. q If the clearance between the parts exceeds the clearance limit, they must be replaced or repaired. q

6.

Interference limit The allowable maximum interference between the hole of a part and the shaft of another part to be assembled is called the “interference limit”. q The interference limit shows the repair limit of the part of smaller tolerance. q If the interference between the parts exceeds the interference limit, they must be replaced or repaired. q

95E-5 Series


Handling electric equipment and hydraulic component

SEN02122-00

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, connectors used for connecting and disconnecting one wire from another wire, and protectors or tubes used for protecting the wiring. Compared with other electrical components fitted 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 (defective contact between male and female) Problems with defective contact are likely to occur because the male connector is not properly inserted into the female connector, or because one or both of the connectors is deformed or the position is not correctly aligned, or because there is corrosion or oxidization of the contact surfaces. The corroded or oxidized contact surfaces may become shiny again (and contact may become normal) by connecting and disconnecting the connector about 10 times. 2)

Defective crimping or soldering of connectors The pins of the male and female connectors are in contact at the crimped terminal or soldered portion, but if there is excessive force brought to bear on the wiring, the plating at the joint will peel and cause improper connection or breakage.

95E-5 Series

11

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12

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 soldering may be damaged, or the wiring may be broken.

4)

High-pressure water entering connector The connector is designed to make it difficult for water to enter (drip-proof structure), 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-circuited 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 surface 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 compressed 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 compressed air, the contacts will become even dirtier, so remove the oil and water from the compressed air completely before cleaning with compressed air.


95E-5 Series


3.

SEN02122-00

Removing, installing, and drying connectors and wiring harnesses 1) Disconnecting connectors 1] Hold the connectors when disconnecting. 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 connectors apart. a Never pull with one hand. 2] q

When removing from clips 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 stoppers. 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 connectors 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 disassembled for a long time, it is particularly easy for improper contact to occur, so always cover the connector.

95E-5 Series

13

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2)

14


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 damage to the connector pins. Check that there is no damage or breakage to the outside of the connector. 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 breakage, 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 stopper clicks into position. 3] Correct any protrusion of the boot and any misalignment of the wiring harness. For connectors fitted with boots, correct any protrusion of the boot. In addition, if the wiring harness is misaligned, or the clamp is out of position, adjust it to its correct position. a If the connector cannot be corrected 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.

95E-5 Series


3)

Heavy duty wire connector (DT 8-pole, 12pole) 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) horizontally 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

SEN02122-00

q

Disconnection

q

Connection (Example of incomplete setting of (a))

15

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4)

16


Drying wiring harness If there is any oil or dirt on the wiring harness, 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 follows. 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 compressed 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 connector. After drying, leave the wiring harness disconnected and carry out a continuity test to check for any short circuits between pins caused by water. a After completely drying the conn e c t o r, b l o w i t w i t h c o n ta c t restorer and reassemble.

95E-5 Series


4.

Handling controller 1) The controller contains a microcomputer and electronic control circuits. These control 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 controller. 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 connectors 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 disconnecting 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 connectors before going on to the next step. a If the power is turned ON with the connectors still disconnected, unnecessary abnormality displays will be generated. 4) When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or current), move the related wiring and connectors several times and check that there is no change in the reading of the tester. a If there is any change, there is probably defective contact in that circuit.

95E-5 Series

SEN02122-00

17

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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 performance 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 cleaning 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 equipment, 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 circuit. The oil cleaning equipment is used to remove the ultra fine (about 3 m) particles that the filter built in the hydraulic equipment cannot remove, so it is an extremely effective device.

95E-5 Series

SEN02122-00

19

SEN02122-00


Connectors newly used for Tier 3 engines 1.

Slide lock type (FRAMATOME-3, FRAMATOME-2) q 107 – 170, 12V140 engines q Various pressure sensors and NE speed sensor Examples) Intake air pressure in intake manifold: PIM (125, 170, 12V140 engines) Oil pressure sensor: POIL (125, 170, 12V140 engines) Oil pressure switch (107, 114 engines) Ne speed sensor of flywheel housing: NE (107 – 170, 12V140 engines) Ambient pressure sensor: PAMB (125, 170, 12V140 engines)

2.

Pull lock type (PACKARD-2) 107 – 170, 12V140 engine q Various temperature sensors Example) Intake air temperature sensor in intake manifold: TIM Fuel temperature sensor: TFUEL Oil temperature sensor: TOIL Coolant temperature sensor: TWTR, etc. Disconnect the connector by pulling lock (B) (on the wiring harness side) of connector (2) outward.

q

Disconnect connector (1) according to the following procedure. 1) Slide lock (L1) to the right. 2) While pressing lock (L2), pull out connector (1) toward you. a Even if lock (L2) is pressed, connector (1) cannot be pulled out toward you, if part A does not float. In this case, float part A with a small screwdriver while press lock (L2), and then pull out connector (1) toward you.

20

95E-5 Series


3.

SEN02122-00

Push lock type q 107, 114 engines Example) Fuel pressure sensor in common rail (BOSCH-03) Disconnect connector (3) according to the following procedure. 1) While pressing lock (C), pull out connector (3) in the direction of the arrow. q

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.

107 engine

a

2)

If the lock is on the underside, use flat-head screwdriver [1] since you cannot insert your fingers. While pressing up lock (C) of the connector with flat-head screwdriver [1], pull out connector (3) in the direction of the arrow.

95E-5 Series

21

SEN02122-00

q

4)

125 – 170, 12V140 engine While pressing lock (E) of the connector, pullout connector (5) in the direction of the arrow. Example) Fuel pressure in common rail: PFUEL etc. (AMP-3)


4.

Turn-housing type (Round green connector) q 140 engine Example) Intake air pressure sensor in intake manifold (CANNON-04): PIM etc. 1)

Disconnect connector (6) according to the 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 harness side.

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) Injection pressure control valve of fuel supply pump: PCV (SUMITOMO-2)

Example) Speed sensor of fuel supply pump: G (SUMITOMO-3) a Pull the connector straight up.

22

95E-5 Series


SEN02122-00

How to read electric wire code a

1

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 symbols. 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 nominal 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 indicated.)

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) Type Low-voltage wire for automobile Thin-cover low-voltage wire for automobile

Symbol AV

AVS

Heat-resistant low-voltAEX age wire for automobile

95E-5 Series

Material Conductor Insulator Conductor

Annealed copper for electric appliance Soft polyvinyl chloride Annealed copper for electric appliance

Insulator

Soft polyvinyl chloride

Conductor

Annealed copper for electric appliance Heat-resistant crosslinked polyethylene

Insulator

Using temperature range (°C)

Example of use General wiring (Nominal No. 5 and above)

–30 to +60 General wiring (Nominal No. 3 and below) General wiring in extremely –50 to +110 cold district, wiring at high-temperature place

23

SEN02122-00

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 – CovAV Standard – – – – – – – 4.6 er D AEX Standard 2.0 2.2 2.7 3.0 3.1 – 3.8 4.6

Nominal No. Number of strands/Diameter of strand Conductor Sectional area (mm2) d (approx.) AVS Standard CovAV Standard er D AEX Standard

8

15

20

30

40

50

60

85

100

50/0.45

84/0.45

41/0.80

70/0.80

85/0.80

7.95

13.36

20.61

35.19

42.73

54.29

63.84

84.96

109.1

3.7 – 5.5 5.3

4.8 – 7.0 7.0

6.0 – 8.2 8.2

8.0 – 10.8 10.8

8.6 – 11.4 11.4

9.8 – 13.0 13.0

10.4 – 13.6 13.6

12.0 – 16.0 16.0

13.6 – 17.6 17.6

108/0.80 127/0.80 169/0.80 217/0.80

“f” of nominal No. denotes flexible”.

24

95E-5 Series


3.

SEN02122-00

Color codes table

(Table 3) Color Code B Br BrB BrR BrW BrY Ch Dg G GB GL Gr GR GW GY L LB Lg LgB LgR

Color of wire

Color Code LgW LgY LR LW LY O P R RB RG RL RW RY Sb Y YB YG YL YR YW

Black Brown Brown & Black Brown & Red Brown & White Brown & Yellow Charcoal Dark green Green Green & Black Green & Blue Gray Green & Red Green & White Green & Yellow Blue Blue & Black Light green Light green & Black Light green & Red

Color of wire Light green & White Light green & Yellow Blue & Red Blue & White Blue & Yellow Orange Pink Red Red & Black Red & Green Red & Blue Red & White Red & Yellow Sky Blue Yellow Yellow & Black Yellow &Green Yellow & Blue Yellow & Red 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 Charge Ground Start Light Instrument Signal Type of circuit Others

95E-5 Series

AVS or AV R B R RW Y G L Br Lg O Gr P Sb Dg Ch

AEX

WG

–

–

–

–

–

–

–

–

–

–

R B R D Y G L

–

–

– –

–

–

–

–

–

RB YR GW LW BrW LgR

RY YB GR LR BrR LgY

RG YG GY LY BrY LgB

RL YL GB LB BrB LgW

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

YW GL

– –

Gr Br – –

25

SEN02122-00


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. q q q q q q q q q q

a

Precautions when carrying out removal work If the coolant contains antifreeze, dispose of it correctly. After disconnecting hoses or tubes, cover them or fit plugs to prevent dirt or dust from entering. When draining oil, prepare a container of adequate size to catch the oil. Confirm the match marks showing the installation position, and make match marks in the necessary places before removal to prevent any mistake when assembling. To prevent any excessive force from being applied to the wiring, always hold the connectors when disconnecting the connectors. Do not pull the wires. Fit wires and hoses with tags to show their installation position to prevent any mistake when installing. Check the number and thickness of the shims, and keep in a safe place. When raising components, be sure to use lifting equipment of ample strength. When using forcing screws to remove any components, tighten the forcing screws uniformly in turn. Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from entering after removal. 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 number 02 03 04 05 06 10 12 2)

26

Sleeve nut (elbow end)

07376-70210 07376-70315 07376-70422 07376-70522 07376-70628 07376-71034 07376-71234

02789-20210 02789-20315 02789-20422 02789-20522 02789-20628 07221-21034 07221-21234

Split flange type hoses and tubes Nominal number 04 05

3)

Plug (nut end)

Flange (hose end)

Sleeve head (tube end)

Split flange

07379-00400 07379-00500

07378-10400 07378-10500

07371-30400 07371-30500

If the part is not under hydraulic pressure, the following corks can be used. Nominal number

Part Number

06 08 10 12 14 16 18 20 22 24

07049-00608 07049-00811 07049-01012 07049-01215 07049-01418 07049-01620 07049-01822 07049-02025 07049-02228 07049-02430

Dimensions D d L 6 5 8 8 6.5 11 10 8.5 12 12 10 15 14 11.5 18 16 13.5 20 18 15 22 20 17 25 22 18.5 28 24 20 30

27

07049-02734

27

22.5

34

95E-5 Series


2. q q q q q q q q q q q q q

a

a 3.

SEN02122-00

Precautions when carrying out installation work Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque. Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any. Replace all gaskets, O-rings, cotter pins, and lock plates with new parts. Bend the cotter pins and lock plates securely. When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion with 2 – 3 drops of adhesive. 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. Clean all parts, and correct any damage, dents, burrs, or rust. Coat rotating parts and sliding parts with engine oil. When press fitting parts, coat the surface with anti-friction compound (LM-P). After fitting snap rings, check that the snap ring is fitted securely in the ring groove. When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect securely. When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align the direction of the hook. When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side. 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. When using the machine for the first time after repair or long storage, follow the same procedure. 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 specified 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. If any part is loosened or damaged, retighten or repair it. Fuel system Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel leakage. If any part is loosened or damaged, retighten or repair it.

95E-5 Series

27

SEN02122-00

4)

5)

28


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. 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”.

95E-5 Series


SEN02122-00

Method of disassembling and connecting push-pull type coupler k k

1

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. 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

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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 hexagonal 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 disconnect it. (Fig. 8)

2.

Connection q Hold the tightening portion and push body (7) straight until sliding prevention ring (6) contacts contact surface (a) of the hexagonal portion at the male end. (Fig. 9)

30

95E-5 Series


SEN02122-00

Type 3 1.

Disconnection 1) Hold the tightening portion and push body (9) straight until sliding prevention ring (8) contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 10) 2) While holding the condition of Step 1), push cover (10) straight until it contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 11) 3) While holding the condition of Steps 1) and 2), pull out whole body (9) to disconnect 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 hexagonal portion at the male end. (Fig. 13)

95E-5 Series

31

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Standard tightening torque table 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 mm 6 8 10 12 14 16 18 20 22 24 27 30 33 36 39 a

a Fig. A

Width across flats mm 10 13 17 19 22 24 27 30 32 36 41 46 50 55 60

Tightening torque Nm kgm 11.8 – 14.7 1.2 – 1.5 27 – 34 2.8 – 3.5 59 – 74 6.0 – 7.5 98 – 123 10.0 – 12.5 153 – 190 15.5 – 19.5 235 – 285 23.5 – 29.5 320 – 400 33.0 – 41.0 455 – 565 46.5 – 58.0 610 – 765 62.5 – 78.0 785 – 980 80.0 – 100.0 1,150 – 1,440 118 – 147 1,520 – 1,910 155 – 195 1,960 – 2,450 200 – 250 2,450 – 3,040 250 – 310 2,890 – 3,630 295 – 370

The following table corresponds to the bolts in Fig. B.

Thread diameter of bolt mm 6 8 10 12

32

1

Width across flats mm 10 13 14 27

Tightening torque Nm 5.9 – 9.8 13.7 – 23.5 34.3 – 46.1 74.5 – 90.2

kgm 0.6 – 1.0 1.4 – 2.4 3.5 – 4.7 7.6 – 9.2

a Fig. B

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.

Thread diameter of bolt mm 10 12 16

3.

Width across flats mm 14 17 22

Tightening torque Nm kgm 59 – 74 6.0 – 7.5 98 – 123 10.0 – 12.5 235 – 285 23.5 – 29.5

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.

Nominal No. 02 03,04 05,06 10,12 14

4.

SEN02122-00

Thread diameter mm 14 20 24 33 42

Width across flats mm

Tightening torque Nm {kgm} Range Target 35 – 63 { 3.5 – 6.5} 44 { 4.5} 84 – 132 { 8.5 – 13.5} 103 {10.5} Varies depending 157 {16.0} on type of connec- 128 – 186 {13.0 – 19.0} tor. 363 – 480 {37.0 – 49.0} 422 {43.0} 746 – 1,010 {76.0 – 103} 883 {90.0}

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 No. 08 10 12 14 16 18 20 24 30 33 36 42 52

95E-5 Series

Thread diameter mm 8 10 12 14 16 18 20 24 30 33 36 42 52

Width across flats mm 14 17 19 22 24 27 30 32 32 – 36 – –

Tightening torque Nm {kgm} Range Target 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75} 9.81 – 12.74 {1.0 – 1.3} 11.27 {1.15} 14.7 – 19.6 {1.5 – 2.0} 17.64 {1.8} 19.6 – 24.5 {2.0 – 2.5} 22.54 {2.3} 24.5 – 34.3 {2.5 – 3.5} 29.4 {3.0} 34.3 – 44.1 {3.5 – 4.5} 39.2 {4.0} 44.1 – 53.9 {4.5 – 5.5} 49.0 {5.0} 58.8 – 78.4 {6.0 – 8.0} 68.6 {7.0} 93.1 – 122.5 { 9.5 – 12.5} 107.8 {11.0} 107.8 – 147.0 {11.0 – 15.0} 127.4 {13.0} 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5} 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5} 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0}

33

SEN02122-00

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}

Nominal No. of hose

Width across flats

02

19

03 04 05 06 (10) (12) (14)

6.

22 24 27 32 36 41 46 55

Range 34 – 54 { 3.5 – 5.5} 34 – 63 { 3.5 – 6.5} 54 – 93 { 5.5 – 9.5} 59 – 98 { 6.0 – 10.0} 84 – 132 { 8.5 – 13.5} 128 – 186 {13.0 – 19.0} 177 – 245 {18.0 – 25.0} 177 – 245 {18.0 – 25.0} 197 – 294 {20.0 – 30.0} 246 – 343 {25.0 – 35.0}

Target

44 { 4.5} 74 { 7.5} 78 { 8.0} 103 {10.5} 157 {16.0} 216 {22.0} 216 {22.0} 245 {25.0} 294 {30.0}

mm 6 8 10 12 14

– 14 – 18 22 24 30 33 36 42

Tightening torque Bolts and nuts Nm 10 ± 2 24 ± 4 43 ± 6 77 ± 12 —

kgm 1.02 ± 0.20 2.45 ± 0.41 4.38 ± 0.61 7.85 ± 1.22 —

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 mm 6 8 10 12 14

34

Thread size (mm)

Face seal Nominal No. Thread diameNumber of ter (mm) (Refthreads, type of erence) thread 9/16-18UN 14.3 – – 11/16-16UN 17.5 – – 13/16-16UN 20.6 1-14UNS 25.4 1-3/16-12UN 30.2 – – – – – –

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. Thread size

7.

Taper seal

Tightening torque Nm 8±2 10 ± 2 12 ± 2 24 ± 4 36 ± 5

kgm 0.81 ± 0.20 1.02 ± 0.20 1.22 ± 0.20 2.45 ± 0.41 3.67 ± 0.51

95E-5 Series


8.

SEN02122-00

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 inch 1/16 1/8 1/4 3/8 1/2 3/4 1

95E-5 Series

Tightening torque Nm 3±1 8±2 12 ± 2 15 ± 2 24 ± 4 36 ± 5 60 ± 9

kgm 0.31 ± 0.10 0.81 ± 0.20 1.22 ± 0.20 1.53 ± 0.20 2.45 ± 0.41 3.67 ± 0.51 6.12 ± 0.92

35

SEN02122-00


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 horizontal 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

(A)

36

(B)

0 10 20 30 40

0 0 0.394 0.787 1.181 1.575

1 0.039 0.433 0.827 1.220 1.614

2 0.079 0.472 0.866 1.260 1.654

3 0.118 0.512 0.906 1.299 1.693

4 0.157 0.551 0.945 1.339 1.732

50 60 70 80 90

1.969 2.362 2.756 3.150 3.543

2.008 2.402 2.795 3.189 3.583

2.047 2.441 2.835 3.228 3.622

2.087 2.480 2.874 3.268 3.661

2.126 2.520 2.913 3.307 3.701

5 0.197 0.591 0.984 1.378 1.772 (C) 2.165 2.559 2.953 3.346 3.740

6 0.236 0.630 1.024 1.417 1.811

7 0.276 0.669 1.063 1.457 1.850

2.205 2.598 2.992 3.386 3.780

2.244 2.638 3.032 3.425 3.819

1 mm = 0.03937 in 8 9 0.315 0.354 0.709 0.748 1.102 1.142 1.496 1.536 1.890 1.929 2.283 2.677 3.071 3.465 3.858

2.323 2.717 3.110 3.504 3.898

95E-5 Series


SEN02122-00

Millimeters to inches

0 10 20 30 40

0 0 0.394 0.787 1.181 1.575

1 0.039 0.433 0.827 1.220 1.614

2 0.079 0.472 0.866 1.260 1.654

3 0.118 0.512 0.906 1.299 1.693

4 0.157 0.551 0.945 1.339 1.732

5 0.197 0.591 0.984 1.378 1.772

6 0.236 0.630 1.024 1.417 1.811

1 mm = 0.03937 in 7 8 9 0.276 0.315 0.354 0.669 0.709 0.748 1.063 1.102 1.142 1.457 1.496 1.536 1.850 1.890 1.929

50 60 70 80 90

1.969 2.362 2.756 3.150 3.543

2.008 2.402 2.795 3.189 3.583

2.047 2.441 2.835 3.228 3.622

2.087 2.480 2.874 3.268 3.661

2.126 2.520 2.913 3.307 3.701

2.165 2.559 2.953 3.346 3.740

2.205 2.598 2.992 3.386 3.780

2.244 2.638 3.032 3.425 3.819

1 kg = 2.2046 lb 6 7 8 9 13.23 15.43 17.64 19.84 35.27 37.48 39.68 41.89 57.32 59.53 61.73 63.93 79.37 81.57 83.78 85.98 101.41 103.62 105.82 108.03

2.283 2.677 3.071 3.465 3.858

2.323 2.717 3.110 3.504 3.898

Kilogram to pound

0 10 20 30 40

0 0 22.05 44.09 66.14 88.18

1 2.20 24.25 46.30 68.34 90.39

2 4.41 26.46 48.50 70.55 92.59

3 6.61 28.66 50.71 72.75 94.80

4 8.82 30.86 51.91 74.96 97.00

5 11.02 33.07 55.12 77.16 99.21

50 60 70 80 90

110.23 132.28 154.32 176.37 198.42

112.44 134.48 156.53 178.57 200.62

114.64 136.69 158.73 180.78 202.83

116.85 138.89 160.94 182.98 205.03

119.05 141.10 163.14 185.19 207.24

121.25 143.30 165.35 187.39 209.44

123.46 145.51 167.55 189.60 211.64

125.66 147.71 169.76 191.80 213.85

127.87 149.91 171.96 194.01 216.05

130.07 152.12 174.17 196.21 218.26

Liters to U.S. Gallons

0 10 20 30 40

0 1 2 0 0.264 0.528 2.642 2.906 3.170 5.283 5.548 5.812 7.925 8.189 8.454 10.567 10.831 11.095

3 0.793 3.434 6.076 8.718 11.359

4 1.057 3.698 6.340 8.982 11.624

1 l = 0.2642 U.S.Gal 5 6 7 8 9 1.321 1.585 1.849 2.113 2.378 3.963 4.227 4.491 4.755 5.019 6.604 6.869 7.133 7.397 7.661 9.246 9.510 9.774 10.039 10.303 11.888 12.152 12.416 12.680 12.944

50 60 70 80 90

13.209 15.850 18.492 21.134 23.775

14.001 16.643 19.285 21.926 24.568

14.265 16.907 19.549 22.190 24.832

14.529 17.171 19.813 22.455 25.096

95E-5 Series

13.473 16.115 18.756 21.398 24.040

13.737 16.379 19.020 21.662 24.304

14.795 17.435 20.077 22.719 25.361

15.058 17.700 20.341 22.983 25.625

15.322 17.964 20.605 23.247 25.889

15.586 18.228 20.870 23.511 26.153

37

SEN02122-00


Liters to U.K. Gallons

0 10 20 30 40

0 0 2.200 4.399 6.599 8.799

1 0.220 2.420 4.619 6.819 9.019

2 0.440 2.640 4.839 7.039 9.239

3 0.660 2.860 5.059 7.259 9.459

4 0.880 3.080 5.279 7.479 9.679

5 1.100 3.300 5.499 7.699 9.899

50 60 70 80 90

10.998 13.198 15.398 17.598 19.797

11.281 13.418 15.618 17.818 20.017

11.438 13.638 15.838 18.037 20.237

11.658 13.858 16.058 18.257 20.457

11.878 14.078 16.278 18.477 20.677

12.098 14.298 16.498 18.697 20.897

1 l = 0.21997 U.K.Gal 6 7 8 9 1.320 1.540 1.760 1.980 3.520 3.740 3.950 4.179 5.719 5.939 6.159 6.379 7.919 8.139 8.359 8.579 10.119 10.339 10.559 10.778 12.318 14.518 16.718 18.917 21.117

12.528 14.738 16.938 19.137 21.337

12.758 14.958 17.158 19.357 21.557

12.978 15.178 17.378 19.577 21.777

kgm to ft.lb

0 10 20 30 40

0 0 72.3 144.7 217.0 289.3

1 7.2 79.6 151.9 224.2 296.6

2 14.5 86.8 159.1 231.5 303.8

3 21.7 94.0 166.4 238.7 311.0

4 28.9 101.3 173.6 245.9 318.3

5 36.2 108.5 180.8 253.2 325.5

6 43.4 115.7 188.1 260.4 332.7

1 kgm = 7.233 ft.lb 7 8 9 50.6 57.9 65.1 123.0 130.2 137.4 195.3 202.5 209.8 267.6 274.9 282.1 340.0 347.2 354.4

50 60 70 80 90

361.7 434.0 506.3 578.6 651.0

368.9 441.2 513.5 585.9 658.2

376.1 448.5 520.8 593.1 665.4

383.4 455.7 528.0 600.3 672.7

390.6 462.9 535.2 607.6 679.9

397.8 470.2 542.5 614.8 687.1

405.1 477.4 549.7 622.0 694.4

412.3 484.6 556.9 629.3 701.6

419.5 491.8 564.2 636.5 708.8

426.8 499.1 571.4 643.7 716.1

100 110 120 130 140

723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7

150 160 170 180 190

1084.9 1157.3 1129.6 1301.9 1374.3

38

1092.2 1164.5 1236.8 1309.2 1381.5

1099.4 1171.7 1244.1 1316.4 1388.7

1106.6 1179.0 1251.3 1323.6 1396.0

1113.9 1186.2 1258.5 1330.9 1403.2

1121.1 1193.4 1265.8 1338.1 1410.4

1128.3 1200.7 1273.0 1345.3 1417.7

1135.6 1207.9 1280.1 1352.6 1424.9

1142.8 1215.1 1287.5 1359.8 1432.1

1150.0 1222.4 1294.7 1367.0 1439.4

95E-5 Series


SEN02122-00

kg/cm2 to lb/in2

0 10 20 30 40

0 0 142.2 284.5 426.7 568.9

1 14.2 156.5 298.7 440.9 583.2

2 28.4 170.7 312.9 455.1 597.4

3 42.7 184.9 327.1 469.4 611.6

4 56.9 199.1 341.4 483.6 625.8

5 71.1 213.4 355.6 497.8 640.1

6 85.3 227.6 369.8 512.0 654.3

1 kg/cm2 = 14.2233 lb/in2 7 8 9 99.6 113.8 128.0 241.8 256.0 270.2 384.0 398.3 412.5 526.3 540.5 554.7 668.5 682.7 696.9

50 60 70 80 90

711.2 853.4 995.6 1,138 1,280

725.4 867.6 1,010 1,152 1,294

739.6 881.8 1,024 1,166 1,309

753.8 896.1 1,038 1,181 1,323

768.1 910.3 1,053 1,195 1,337

782.3 924.5 1,067 1,209 1,351

796.5 938.7 1,081 1,223 1,365

810.7 953.0 1,095 1,237 1,380

825.0 967.2 1,109 1,252 1,394

839.2 981.4 1,124 1,266 1,408

100 110 120 130 140

1,422 1,565 1,707 1,849 1,991

1,437 1,579 1,721 1,863 2,005

1,451 1,593 1,735 1,877 2,020

1,465 1,607 1,749 1,892 2,034

1,479 1,621 1,764 1,906 2,048

1,493 1,636 1,778 1,920 2,062

1,508 1,650 1,792 1,934 2,077

1,522 1,664 1,806 1,949 2,091

1,536 1,678 1,821 1,963 2,105

1,550 1,693 1,835 1,977 2,119

150 160 170 180 190

2,134 2,276 2,418 2,560 2,702

2,148 2,290 2,432 2,574 2,717

2,162 2,304 2,446 2,589 2,731

2,176 2,318 2,460 2,603 2,745

2,190 2,333 2,475 2,617 2,759

2,205 2,347 2,489 2,631 2,773

2,219 2,361 2,503 2,646 2,788

2,233 2,375 2,518 2,660 2,802

2,247 2,389 2,532 2,674 2,816

2,262 2,404 2,546 2,688 2,830

200 210 220 230 240

2,845 2,987 3,129 3,271 3,414

2,859 3,001 3,143 3,286 3,428

2,873 3,015 3,158 3,300 3,442

2,887 3,030 3,172 3,314 3,456

2,901 3,044 3,186 3,328 3,470

2,916 3,058 3,200 3,343 3,485

2,930 3,072 3,214 3,357 3,499

2,944 3,086 3,229 3,371 3,513

2,958 3,101 3,243 3,385 3,527

2,973 3,115 3,257 3,399 3,542

95E-5 Series

39

SEN02122-00


Temperature Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centigrade 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 Fahrenheit 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 Centigrade values, and read the corresponding Fahrenheit temperature on the right.

°C

°F

°C

°F

°C

°F

°C

1°C = 33.8°F °F

–40.4 –37.2 –34.4 –31.7 –28.9

–40 –35 –30 –25 –20

–40.0 –31.0 –22.0 –13.0 –4.0

–11.7 –11.1 –10.6 –10.0 –9.4

11 12 13 14 15

51.8 53.6 55.4 57.2 59.0

7.8 8.3 8.9 9.4 10.0

46 47 48 49 50

114.8 116.6 118.4 120.2 122.0

27.2 27.8 28.3 28.9 29.4

81 82 83 84 85

177.8 179.6 181.4 183.2 185.0

–28.3 –27.8 –27.2 –26.7 –26.1

–19 –18 –17 –16 –15

–2.2 –0.4 1.4 3.2 5.0

–8.9 –8.3 –7.8 –7.2 –6.7

16 17 18 19 20

60.8 62.6 64.4 66.2 68.0

10.6 11.1 11.7 12.2 12.8

51 52 53 54 55

123.8 125.6 127.4 129.2 131.0

30.0 30.6 31.1 31.7 32.2

86 87 88 89 90

186.8 188.6 190.4 192.2 194.0

–25.6 –25.0 –24.4 –23.9 –23.3

–14 –13 –12 –11 –10

6.8 8.6 10.4 12.2 14.0

–6.1 –5.6 –5.0 –4.4 –3.9

21 22 23 24 25

69.8 71.6 73.4 75.2 77.0

13.3 13.9 14.4 15.0 15.6

56 57 58 59 60

132.8 134.6 136.4 138.2 140.0

32.8 33.3 33.9 34.4 35.0

91 92 93 94 95

195.8 197.6 199.4 201.2 203.0

–22.8 –22.2 –21.7 –21.1 –20.6

–9 –8 –7 –6 –5

15.8 17.6 19.4 21.2 23.0

–3.3 –2.8 –2.2 –1.7 –1.1

26 27 28 29 30

78.8 80.6 82.4 84.2 86.0

16.1 16.7 17.2 17.8 18.3

61 62 63 64 65

141.8 143.6 145.4 147.2 149.0

35.6 36.1 36.7 37.2 37.8

96 97 98 99 100

204.8 206.6 208.4 210.2 212.0

–20.0 –19.4 –18.9 –18.3 –17.8

–4 –3 –2 –1 0

24.8 26.6 28.4 30.2 32.0

–0.6 0 0.6 1.1 1.7

31 32 33 34 35

87.8 89.6 91.4 93.2 95.0

18.9 19.4 20.0 20.6 21.1

66 67 68 69 70

150.8 152.6 154.4 156.2 158.0

40.6 43.3 46.1 48.9 51.7

105 110 115 120 125

221.0 230.0 239.0 248.0 257.0

–17.2 –16.7 –16.1 –15.6 –15.0

1 2 3 4 5

33.8 35.6 37.4 39.2 41.0

2.2 2.8 3.3 3.9 4.4

36 37 38 39 40

96.8 98.6 100.4 102.2 104.0

21.7 22.2 22.8 23.3 23.9

71 72 73 74 75

159.8 161.6 163.4 165.2 167.0

54.4 57.2 60.0 62.7 65.6

130 135 140 145 150

266.0 275.0 284.0 293.0 302.0

–14.4 –13.9 –13.3 –12.8 –12.2

6 7 8 9 10

42.8 44.6 46.4 48.2 50.0

5.0 5.6 6.1 6.7 7.2

41 42 43 44 45

105.8 107.6 109.4 111.2 113.0

24.4 25.0 25.6 26.1 26.7

76 77 78 79 80

168.8 170.6 172.4 174.2 176.0

68.3 71.1 73.9 76.7 79.4

155 160 165 170 175

311.0 320.0 329.0 338.0 347.0

40

95E-5 Series

SEN02122-00



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 SAA4D95LE-5

2

Engine serial No.

Machine models PC138US-8, PC138USLC-8

Hydraulic excavator

95E-5 Series

01 Specification

SEN02124-00

2. Outline of direct injection engine q

The engine has passed strict emission regulations (EPA Regulations of USA, Regulations of EU and Construction machinery regulations of Japan) and attained a small size, light weight, high output, low fuel consumption, low noise, high reliability and high durability, and is suitable various construction machinery and industrial machinery.

q

The engine is an in-line, vertical, water-cooled, direct fuel injection and 4-stroke diesel engine which has the following features.

1)

Small-sized and light-weight engine q Since no liners are used in the engine block, the distance between the cylinders is reduced, thus the overall length of the engine is reduced. q The stroke bore ratio is as large as 115 mm/95 mm. The overall height of the engine is reduced, however, by reducing the distance between the big end center and small end center of the connecting rod. q The heads of the cylinder head and cylinder block are thinned and light-weighted but their strength is maintained. q Each part is designed economically for weight reduction by applying reliability analysis technologies.

2)

High performance engine q Combustion efficiency is improved and cleaner exhaust ga s is obta ined by designing the air intake port of less suction resistance and employing the 2-stage combustion chamber. q Friction loss horsepower is reduced by light-weighting the main moving parts and setting the capacity of the auxiliary components (water pump and oil pump) to proper level. q Weight, noise and vibration are reduced by setting the clearance between the piston and cylinder properly.

95E-5 Series

3)

Other features q Noise is reduced by improving the piston shape and float-mounting the head cover. q Reliability and durability of the engine are increased with the development technologies based on the long experience and achievement in development of construction machinery and industrial engines.

3. Outline of SAA4D95LE-5 engine q

The SAA4D95LE-5 engine is based on the SAA4D95LE-3 engine having a good record and meets the 3rd emission regulation (Tier 3) by employing the high-pressure common rail injection system and improving the combustion chamber etc. The SAA4D95LE-5 engine is made by improving the SAA4D95LE-3 engine in the following items.

1)

Employment of high-pressure common rail fuel injection system q Low emission and low noise are attained and good combustion is maintained by high-pressure injection, flexibility in the injection timing and multiple injection.

2)

Improvement of combustion chamber q Production of nitrogen oxides (NOx) in the exhaust gas is reduced by controlling the early combustion with the 2-stage combustion concept. Fuel is mixed with more air and burnt well in the late combustion period. As a result, less smoke is emitted.

3)

Improvement of turbocharger q The turbocharger of a high pressure ratio is employed.

3

SEN02124-00

01 Specification

Specifications

1 Engine name

SAA4D95LE-5

Machine models

PC138US-8, PC138USLC-8

Number of cylinders – Bore × Stroke Total displacement Firing order

mm

Overall length

mm

994

Overall width

mm

714

Overall height (excluding exhaust pipe)

mm

—

Overall height (including exhaust pipe)

mm

1,219

Rated output

kW{HP}/rpm

72.1 {96.6}/2,200 (Gross)

Max. torque

Nm{kgm}/rpm

358 {36.5}/1,500 (Gross)

No-load max. speed (High idle speed)

rpm

2,300 ± 60

No-load min. speed (Low idle speed)

rpm

1,100 ± 50

g/kW·h {g/HP·h}

239 {178}

Dry weight

kg

332

Fuel supply pump Governor

— —

Bosch CP1H-OHW (HPCR) Electronic control type

Quantity of lubricating oil (Refill capacity)

l

11 (12)

Quantity of coolant

l

(Engine side: 4.5)

Alternator Starting motor Battery

— — —

24 V, 35 A 24 V, 4.5 kW 12 V, 64 Ah × 2

Turbocharger Air compressor Others

— — —

TD04L — With air-cooled aftercooler

Performance

Dimensions

—

4 – 95 × 115 3.260 {3,260} 1–2–4–3

Fuel consumption ratio at rated point

4

l{cc}

95E-5 Series

01 Specification

General view

SEN02124-00

1

Left side view of engine

a

The shape is subject to machine models.

1. 2.

Center of crankshaft Rear face of flywheel housing

95E-5 Series

5

SEN02124-00

01 Specification

Front view of engine

a


1. 2.

Center of crankshaft Center of cylinder

6

95E-5 Series

01 Specification

SEN02124-00

Dimensions table Unit: mm Engine SAA4D95LE-5

Machine model PC138US-8, PC138USLC-8

Dimension of each part A

B

C

D

E

F

G

H

J

825

169

994

312

907

1,219

382

332

714

a These dimensions are given for reference when the engine is set on a test bench.

95E-5 Series

7

SEN02124-00

01 Specification

Weight table

1 Unit: kg

No.

8

Item

Main parts

SAA4D95LE-5

1

Turbocharger

TD04L

5

2

Cylinder head assembly

Cylinder head, valve, valve spring

30

3

Cylinder block assembly

Cylinder block, main metal block, cylinder liner

71

4

Gear case (front cover)

2.6

5

Oil pan

4.4

6

Flywheel assembly

7

Flywheel housing assembly

8

Crankshaft assembly

Crankshaft, crank gear

26.1

9

Camshaft assembly

Camshaft, cam gear, thrust plate

5.2

10

Piston and connecting rod assembly

Piston, piston ring, piston pin, connecting rod

11

Oil pump

0.6

12

Supply pump

6.1

13

Water pump

7.4

14

Alternator

15

Starting motor

16

Air compressor

—

17

Aftercooler assembly

—

Flywheel ring gear

26.6 25

2.4 × 4

24 V, 35 A

4.7

24 V, 60 A

6.3

24 V, 4.5 kW

8.5

95E-5 Series

01 Specification

SEN02124-00

Engine performance curves Engine SAA4D95LE-5

95E-5 Series

Engine serial No.

1 Machine model


Page 10

9

SEN02124-00

01 Specification

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



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


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

SEN02126-00


General structure

a


1. Crankshaft pulley 2. Front oil seal 3. Crankshaft 4. Crankshaft gear 5. Connecting rod 6. Camshaft bushing 7. Camshaft gear 8. Front cover 9. Connecting rod bushing 10. Piston pin

4

1

11. Oil ring 12. Second ring 13. Top ring 14. Fan pulley 15. Piston 16. Water pump 17. Intake valve 18. Exhaust valve 19. Thermostat 20. Fan

21. Valve guide 22. Valve spring 23. Cylinder head cover 24. Rocker arm bracket 25. Rocker arm spring 26. Cylinder head 27. Cylinder block 28. Push rod 29. Flywheel housing 30. Flywheel

95E-5 Series


31. Ring gear 32. Tappet 33. Main bearing 34. Rear oil seal 35. Thrust bearing 36. Oil pan 37. Camshaft 38. Connecting rod cap 39. Oil filter 40. Exhaust manifold

95E-5 Series

41. Turbocharger 42. Rocker arm 43. Air intake connector 44. Fuel injection injector 45. Air intake manifold 46. Rail 47. Supply pump 48. Starting motor

SEN02126-00

Specifications Type: In-line, 4-cylinder, watercooled, direct fuel injection, 4-cycle diesel engine

5

SEN02126-00


Air intake and exhaust system Air intake and exhaust unit

a

1

1


1. Intake manifold 2. Air connector

6

95E-5 Series


SEN02126-00

A: Air intake inlet B: Exhaust outlet 1. 2. 3. 4.

Muffler Exhaust connector Turbocharger Exhaust manifold

95E-5 Series

7

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Air cleaner

1

FPG type

a


A: Air intake inlet B: Exhaust outlet 1. 2. 3. 4. 5.

Inlet Outlet Guide vane Primary element Safety element

Features (FPG type) q The element diameter is the same and the outside diameter of the body is small. The inlet is placed in the direction of connection, so no guide vane is used; a simple spiral guide vane can give ample centrifugal force. q The dust pan has no guide vane and its structure is simple.

8

6. 7. 8. 9.

Vacuator valve Dust pan Body Element

Structure q Air containing dust is sucked into the tangential from inlet (1). The dust is separated by the centrifugal separation effect of guide vane (3). More than 99.9% of the dust is then removed by primary element (4), and the clean air then passes through safety element (5) and outlet (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 automatically discharged.

95E-5 Series

SEN02126-00

Turbocharger


1

Type: TD04L

a

10


95E-5 Series


A: B: C: D: E: F:

SEN02126-00

Air intake inlet Air intake outlet Exhaust inlet Exhaust outlet Oil inlet 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

24 End play of rotor 25 Radial play of rotor

Criteria

Remedy

Standard

Repair limit

0.010 – 0.076

0.103

0.394 – 0.602

0.720

Repair or replace

Specifications Type: TD04L Exhaust temperature: Max. 700ºC (inlet) Direction of rotation: Clockwise (as seen from blower)

95E-5 Series

11

SEN02126-00


Outline of waste gate valve q

q

q

12

This maintains a suitable supercharging pressure (set supercharging pressure) in order to prevent any excessive load on the engine by suppressing any supercharging above the necessary level from the compressor. In order to do this, waste gate valve (1) is installed in the exhaust circuit before the turbine. 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

Pressure (A) near the outlet port of the compressor passes through (B) and actuates actuator (2). Waste gate valve (1) opens, and part of the exhaust gas bypasses the turbine, so the output of the turbine drops and the set supercharging pressure is maintained.

Point (c) where engine speed (a) and supercharging pressure (b) intersect is the point where the waste gate valves start to open.

95E-5 Series


Muffler

SEN02126-00

1

A: Exhaust gas inlet (From turbocharger) B: Exhaust gas outlet C: Water drain

95E-5 Series

13

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Engine unit

1

Cylinder head

1

a a

14

The shape is subject to machine models. *1: The Nos. in the illustration are the tightening order of the bolts. 95E-5 Series


1. 2. 3. 4. 5. 6. 7.

SEN02126-00

Cylinder head Head cover Oil filler cap Valve guide Bracket Injector for common rail Fuel scatter prevention cover Unit: mm

No.

Item

8

Distortion of cylinder head mounting surface

9

Protrusion of nozzle

Tightening torque of cylinder head mounting bolt (Coat 10 bolt threads and washers with molybdenum disulphide (LM-P))

11

Tightening torque of nozzle holder mounting bolt

Tightening torque of head 12 cover mounting bolt

Criteria

Remedy

Standard

Repair limit

0 – 0.05

0 – 0.30

Repair by grinding or replace

4.62 ± 0.28

4.3 – 4.9

Replace nozzle gasket

Order

Target Nm {kgm}

Range Nm {kgm}

1st step

68.6 {7}

58.8 – 78.5 {6 – 8}

2nd step

3rd step

Tighten bolts in order of Nos. shown in Tightening bolt for plastic region rota- illustration. tion angle 108 {11}

103 – 113 {10.5 – 11.5}

Retighten 90º

90 (+30/0)º

Target Nm {kgm}

Range Nm {kgm}

28.5 {2.9}

27 – 30 {2.8 – 3.1}

8.8 {0.9}

7.8 – 9.8 {0.8 – 1.0}

Retighten

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

SEN02126-00

Cylinder block

a 1. 2. 3. 4. 5. 6. 7. 8.

16


1

The shape is subject to machine models. Main bearing cap Main bearing cap bolt Camshaft bushing (No. 1 journal) Cylinder block Camshaft bushing (No. 2 journal) Camshaft bushing (No. 3 journal) Oil pump drive shaft bushing Oil pump driven shaft

95E-5 Series


SEN02126-00

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

SEN02126-00


(Cam journal No.2 and No.3 : Without bushing)

Unit: mm No. 1

Check item Distortion of cylinder head mounting surface Inside diameter of main bearing hole

2

Roundness of main bearing hole Straightness of main bearing holes

3

Inside diameter of main bearing

4

Inside diameter of cam bushing hole

5

Inside diameter of cam bushing Inside diameter of cylinder block

6

a

18

Tightening torque of main bearing cap mounting bolts (Coat bolt threads and washers with engine oil)

Criteria Standard 0 – 0.08 Standard

Remedy Repair limit 0.15 Tolerance +0.019 +0.000

74 Repair limit: 0.005

Replace by grinding

Repair or replace cylinder block

Repair limit: 0.010 Standard size STD 70.00 0.25 US 69.75 0.50 US 69.50 0.75 US 69.25 1.00 US 69.00 Standard

Tolerance

Repair limit 70.20 69.95 +0.103 69.70 +0.058 69.45 69.20 Tolerance +0.030 53.5 +0.000 Journal Standard Tolerance Repair limit +0.030 No. 1 50.5 50.60 –0.040 No. 2 –0.031 50.5 50.60 No. 3 –0.050 Order Target Nm {kgm} Range Nm {kgm} 1st step 113 {11.5} 108 – 118 {11 – 12} 2nd step 0 {0} Loosen completely 3rd step 132 {13.5} 127 – 137 {13 – 14}

Replace main bearing

Repair or replace cylinder block Replace Press fit bushing Retighten

US: Under Size

95E-5 Series


Cylinder

SEN02126-00

1

Unit: mm No.

Check item

Criteria Standard size

Inside diameter

1

a

STD

95

0.25 OS

95.25

0.50 OS

95.50

Remedy

Tolerance +0.022 +0.000

Roundness of inside diameter

Repair limit: 0.020

Cylindricity of inside diameter

Repair limit: 0.020

Repair limit 95.15 95.40 95.65

Correct with oversize, or install cylinder liner, or replace cylinder block

Measure inside diameter at position 40, 100, and 160 from top surface 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 . overhaul) Rank +0 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 cylinder block 95.50 +0 . and correct 3) If cylinder bore is more than 95.40: Carry out stepped machinmark (S or L) ing of cylinder block and insert cylinder liner. For details of the method for machining the cylinder block and selecting the cylinder liner, see REPAIR AND REPLACEMENT OF PARTS.

OS: Over Size

95E-5 Series

19

SEN02126-00

Main moving parts


1

a: Offset 1. 2. 3. 4. 5. 6. 7. 8. 9.

20

Crankshaft Crankshaft gear (No. of teeth: 24) Main bearing Connecting rod bearing Connecting rod Cylinder block Piston Connecting rod bushing Piston pin

10. Top ring 11. Second ring 12. Oil ring 13. Thrust bearing 14. Connecting rod cap 15. Connecting rod cap bolt 16. Main cap 17. Main cap bolt 18. Cam bushing

95E-5 Series


Specifications Crankshaft q Closed die forging

SEN02126-00

Piston ring

Piston Direct fuel injection type 2-stage combustion chamber q Center of piston hole offset 1.0 mm (to reduce vibration) q

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

SEN02126-00


Crankshaft

1

Unit: mm No. 1

Check item End play

Outside diameter of main journal 2 Roundness of main journal Clearance of main journal

Outside diameter of crankpin journal 3

Criteria Standard

Repair limit

0.131 – 0.351

0.40

Standard size Tolerance Repair limit 70.00 69.86 69.75 69.61 +0.015 69.50 69.36 +0.000 69.25 69.11 69.00 68.86 Repair limit: 0.020 Standard clearance Clearance limit 0.043 – 0.103 0.25 Standard size Tolerance Repair limit STD 57.00 56.91 0.25 US 56.75 56.66 +0.015 0.50 US 56.50 56.41 +0.000 0.75 US 56.25 56.16 1.00 US 56.00 55.91

STD 0.25 US 0.50 US 0.75 US 1.00 US

Roundness of crankpin journal Clearance of crankpin journal

4

a

22

Bend of crankshaft

Remedy Repair by using over size thrust bearing or replace

Repair by using under size bearing or replace

Replace main bearing

Repair by using under size bearing or replace

Repair limit: 0.020 Standard clearance

Clearance limit

0.029 – 0.089

0.22

Repair limit: 0.09 (Total indicated runout)

Replace connecting rod bearing Repair by using under size bearing or replace

US: Under Size

95E-5 Series


Camshaft

SEN02126-00

1

(Bushing installed to journal No. 2 and 3)

Unit: mm No. 1

Check item

Criteria

End play Journal

2

3

Clearance between camshaft and bushing

No.1 No.2 No.3

Curvature of camshaft

Standard size

Repair limit

0.150 – 0.350

0.5 Tolerance

Standard size 50.5

Shaft

Hole

–0.080 –0.110

+0.030 –0.040

Height of camshaft

Intake

42.69

Exhaust

43.04

Valve position

Standard Clearance clearance limit 0.040 – 0.140

Tolerance

a

Valve timing

0.25

Repair limit 42.2

±0.10

Replace bushing

Crankshaft angle

Replace

42.5

When testing (Crankshaft angle when valve has gone down 1 mm) Standard

5

Replace thrust plate

Repair limit: 0.03 (Total deflection of indicator) Standard size

4

Remedy

Intake open

Before TDC

9º

Before TDC

8º

Intake closed

After BDC

20º

After BDC

4º

Exhaust open

Before BDC

52º

Before BDC

37º

Exhaust closed

After TDC

13º

After TDC

12º

Tolerance Check for curvature or wear of valve, camshaft, push rod. Correct or ±3º replace

TDC: Top Dead Center BDC: Bottom Dead Center

95E-5 Series

23

SEN02126-00


Piston, piston ring and piston pin

No.

1

Check item

Criteria

Outside diameter of piston (at right angle to boss)

2 3

1

Piston ring gap

4

Standard size

Repair limit

STD

94.875

94.86

0.25 OS

95.125

95.11

0.50 OS

95.375

95.36

No.

Measuring point

Standard clearance

Clearance limit

2

Top ring

0.28 – 0.38

2.0

3

Second ring

0.40 – 0.50

2.0

4

Oil ring

0.20 – 0.40

1.5

No.

Measuring Standard size point

5 6

Clearance between piston ring groove and piston ring

7

8

a a

24

Clearance between piston and piston pin

Remedy

Tolerance Ring

5

Top ring

2.5

–0.06 –0.08

6

Second ring

2

–0.01 –0.03

7

Oil ring

3

–0.01 –0.03

Standard size 30

Tolerance

Piston

Replace piston (only S size supplied as replacement part)

Replace piston ring

ClearStandard clearance ance limit

*1 Judge using groove wear Replace gauge piston ring or +0.05 0.04 – 0.20 piston +0.03 0.08 +0.04 +0.02

0.03 – 0.07

Shaft

Hole

Standard clearance

–0.000 –0.006

+0.010 +0.004

0.004 – 0.016

0.15

Clearance Replace limit piston or piston pin 0.05

*1: Part No. (wear gauge): 795-901-1130 OS: Over Size

95E-5 Series


SEN02126-00

Connecting rod

1

Unit: mm No.

Check item

1

Clearance between connecting rod bushing and piston pin (carry out reaming after press fitting)

2

Criteria Tolerance

Standard size 30

Inside diameter of connecting rod bushing hole

Shaft

Hole

–0.000 –0.006

+0.033 +0.020

4

5

6

a

Inside diameter of connecting rod bearing

Inside diameter of connecting rod bearing hole

Bend and twist of connecting rod

Tightening torque of connecting rod cap mounting bolts (Coat bolt threads and washers with engine oil)

Clearance Replace bushing (semilimit finished part supplied as 0.020 – 0.10 replacement 0.039 part) Standard clearance

Standard

Tolerance

33

+0.025 +0.000 Standard size

3

Remedy

STD

57.00

0.25 US

56.75

0.50 US

56.50

0.75 US

56.25

1.00 US

56.00

Tolerance

Replace connecting rod

Repair limit 57.20 56.95

+0.095 +0.045

56.70

Replace connecting rod bearing

56.45 56.20

Standard

Tolerance

61

+0.025 +0.000 Standard

Repair limit

Bend (a)

Max. 0.20

0.25

Twist (b)

Max. 0.30

0.35

Dimension (c)

167

—

Dimension (d)

167

—

Order

Target Nm {kgm}

Range Nm {kgm}

1st step

39 {4}

37 – 41 {3.8 – 4.2}

2nd step

Retighten with 90º

90 (+30/0)º

Replace connecting rod

Retighten

Tightening bolt for plastic region rotation angle

US: Under Size

95E-5 Series

25

SEN02126-00


Flywheel and flywheel housing

1

Without rear PTO type

a a

26

The shape is subject to machine models. 12: The Nos. in the illustration are the tightening order of the bolts. 95E-5 Series


1. 2. 3. 4. 5. 6.

SEN02126-00

Starting motor Flywheel housing Crankshaft Rear oil seal (Wet type: Double lip) Flywheel Ring gear (No. of teeth: 127)

No.

Check item

Criteria

Remedy

7

Face runout of flywheel housing

Repair limit: 0.30

8

Radial runout of flywheel housing

Repair limit: 0.30

9

Tightening torque of flywheel housing mounting bolts

Target Nm {kgm}

Range Nm {kgm}

66.2 {6.75}

58.8 – 73.5 {6.0 – 7.5}

10

Radial runout of flywheel

Repair limit: 0.35

11

Face runout of flywheel

Repair limit: 0.30

12

Tightening torque of flywheel mounting bolts (Coat bolt threads and washers with engine oil)

95E-5 Series

Repair by reassembling

Order

Target Nm {kgm}

1st step

88.3 {9.0}

2nd step

191 {19.5}

Retighten Repair by reassembling

Range Nm {kgm} 58.8 – 118 {6.0 – 12.0} Retighten 186 – 196 {19 – 20}

27

SEN02126-00

Timing gear


1

Without front PTO type (Spur gear)

A, B: Match marks for timing gears 1. 2. 3. 4. 5. 6. 7. 8. 9.

28

Camshaft gear (No. of teeth: 52) Idler gear (No. of teeth: 52) Supply pump drive gear (No. of teeth: 31) Crankshaft gear (No. of teeth: 26) Oil pump drive gear (No. of teeth: 22) Shaft Bushing Thrust plate Front seal

95E-5 Series


SEN02126-00

Specification Front oil seal q Single lip with dust seal

95E-5 Series

29

SEN02126-00


(Without front PTO)

Unit: mm No.

1

2

3

30

Check item

Backlash of each gear

Clearance between idler gear bushing and shaft

End play of idler gear

Criteria

Remedy

Measuring point

Gears

Standard

A

Crankshaft gear and idler gear

0.07 – 0.33

B

Idler gear and camshaft gear

0.09 – 0.36

C

Idler gear and supply pump gear

0.06 – 0.33

a

Camshaft gear and oil pump gear

0.07 – 0.33

Standard size 45

Tolerance Shaft

Hole

–0.000 –0.016

+0.083 +0.018

Repair limit

0.4

Replace bushing or gear

Clearance Replace bushing (semilimit finished part supplied as 0.018 – 0.10 replacement 0.099 part) or gear Standard clearance

Standard

Repair limit

0.03 – 0.09

0.20

Replace idler shaft, thrust plate or gear

95E-5 Series

SEN02126-00

Valve system

1. 2. 3. 4. 5. 6. 7. 8. 9.

32

Cam gear (No. of teeth: 52) Thrust plate Camshaft Tappet Push rod Exhaust valve Intake valve Valve spring Valve seal


1

10. Valve cotter 11. Valve stem cap 12. Spring seat 13. Rocker arm spring 14. Rocker arm bracket 15. Rocker arm shaft 16. Adjustment screw 17. Locknut 18. Rocker arm

95E-5 Series


SEN02126-00

Specifications Valve lift q Intake valve: 9.6 mm q Exhaust valve: 10.6 mm

95E-5 Series

33

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Valve, valve guide

a

1

The shape is subject to machine models. Unit: mm

No.

Check item

Criteria

Remedy

Tolerance 1

Sinking of valve

2

Thickness of valve head

3

Valve seat angle

Air intake

Repair limit

1.0 ± 0.18

Exhaust

0.9 ± 0.18 15 ± 1.0

Standard 45º

Clearance between valve guide and valve stem

Installed load of valve spring

Hole

Standard clearance

Clearance limit

Air intake 8

–0.035 –0.050

+0.015 +0.000

0.035 – 0.065

0.20

Exhaust 8

–0.050 –0.065

+0.015 +0.000

0.050 – 0.080

0.20

Standard size

Repair limit

6204-41-4410 (Peach-color)

49.2

48.5

6204-41-4431 (Red)

56.0

55.0

Part No. (distinguishing feature)

Installed length

Standard Installed load N {kg}

Allowable installed load N {kg}

6204-41-4410 (Peach-color)

40.5

181 ± 8.8 {18.5 ± 0.9}

162 {16.5}

6204-41-4431 (Red)

40.5

153 ± 14.7 {15.6 ± 1.5}

127 {13.0}

Out-of-square of valve spring 6

34

Driving-in height of valve guide

Replace

Shaft

Part No.

5

1.00 Repair limit

Tolerance

(distinguishing feature)

Free length of valve spring

Repair valve or valve seat

Correct valve

Judge contact surface or valve seat, condition with vacuum test or replace

± 15’

Standard size 4

Tolerance

1.00

Replace either valve or valve guide or both

Replace

Repair limit: 18.5º Standard size

Tolerance

14.5

± 0.2

Correct

95E-5 Series


SEN02126-00

Rocker arm shaft, push rod and tappet

1

Unit: mm No.

Check item Outside diameter of rocker arm shaft

1

Criteria Standard

Tolerance

19

–0.000 –0.020

19

+0.030 +0.010

Replace rocker arm

Standard clearance

Clearance limit

0.010 – 0.050

0.12

Replace rocker arm or rocker arm shaft

Inside diameter of rocker arm shaft hole Clearance between rocker arm and rocker arm shaft

Remedy

Bend of rocker arm shaft


2

Bend of push rod


3

Tightening torque of rocker arm nut

4

Valve clearance (at warm and cold)

Outside diameter of tappet 5

Inside diameter of tappet hole Clearance between tappet and tappet hole

95E-5 Series

Target Nm {kgm}

Range Nm {kgm}

44 {4.5}

39 – 49 {4 – 5}

Valve

Standard

Tolerance

Air intake

0.35

±0.02

Exhaust

0.50

Replace rocker arm shaft

Replace push rod Retighten

Adjust

±0.02

Standard

Tolerance

16

–0.015 –0.030

16

+0.018 –0.000

Replace cylinder block

Standard clearance

Clearance limit

0.015 – 0.048

0.12

Replace tappet or cylinder block

Replace tappet

35

SEN02126-00



36

SEN02127-00

ENGINE 1SHOP MANUAL

95E-5 Series


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

SEN02127-00


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 Lubrication system diagram

SEN02127-00

1 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

SEN02127-00

Oil pump

1. 2. 3. 4. 5. 6. 7. 8. 9.

4

Bushing Drive gear (No. of teeth: 7) Pump cover Oil pump drive gear (No. of teeth: 22) Drive shaft Driven shaft Driven gear (No. of teeth: 7) Regulator valve Valve spring


1

Specifications Oil pump q Type: Gear pump q Pump speed: Engine speed × 1.182 Regulator valve q Set pressure: 588 ± 49 kPa {6.0 ± 0.5 kg/cm2}

95E-5 Series


SEN02127-00

Unit: mm No.

1

Check item

Axial clearance of pump gear

Criteria Standard size 21

2

3

a

Radial clearance of pump gear

Interference between pump drive gear and drive shaft

Standard size 38 Standard size

Tolerance

Remedy

Gear width

Body width

Standard clearance (End play)

–0.000 –0.016

–0.070 +0.030

0.030 – 0.086

0.10 Clearance limit

Tolerance

Clearance limit (End play)

Replace gear

Gear OD

Body OD

Standard clearance

+0.115 +0.065

+0.245 +0.205

0.045 – 0.090

0.13

Tolerance Shaft

Hole

Standard clearance

Clearance limit

13

–0.024 –0.042

–0.067 –0.085

0.025 – 0.061

—

Replace

4

Clearance between drive shaft and cover

13

–0.024 –0.042

+0.018 +0.000

0.024 – 0.060

—

Replace bushing

5

Interference between pump gear and drive shaft

13

–0.024 –0.042

–0.065 –0.086

0.025 – 0.061

—

Replace

6

Clearance between drive shaft and bushing

13

–0.024 –0.042

+0.048 +0.004

0.028 –

—

Replace bushing

7

Interference between driven shaft and cylinder block

16

–0.064 +0.046

+0.018 +0.000

0.028 – 0.064

—


8

Clearance between driven shaft and gear

13

–0.110 –0.125

–0.065 –0.086

0.024 – 0.060

—

Replace shaft or gear

9

Inside diameter of cylinder block for drive shaft bushing

16

–0.087 +0.060

+0.018 +0.000

0.042 – 0.087

—


0.09

OD: Outer Diameter

95E-5 Series

5

SEN02127-00


Regulator valve

1

Unit: mm No.

1

2

3

6

Check item Clearance between valve and body

Regulator valve spring

Regulator valve set pressure

Criteria Standard size 11

Remedy

Tolerance Shaft

Hole

–0.050 –0.077

+0.020 –0.020

Standard clearance

Replace

0.030 – 0.097

• Free length Standard size: 33.1 • Installed load Installed length

Standard load N {kg}

Load limit N {kg}

27.8

19.7 {2.0}

55.9 {5.7}

Standard: 0.6 ± 0.05 MPa {6.0 ± 0.5 kg/cm2}

Replace

Repair or replace spring

95E-5 Series


Oil filter

SEN02127-00

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

SEN02127-00


Oil filter mounting

a


1. Oil cooler 2. Cartridge 3. Bracket

8

95E-5 Series


Fuel system Fuel system diagram

SEN02127-00

1 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

SEN02127-00

Supply pump

a 1. 2. 3. 4. 5. 6.

10


1

The shape is subject to machine models. High pressure value Inlet valve Piston Cam MPROP (Fuel quantity adjustment solenoid valve) Gear pump

Specifications Supply pump q Type: Bosch type CP1H-OHW q Lubrication method: Lubrication with fuel Governor Type: Electronic control

95E-5 Series


SEN02127-00

Supply pump mounting

A: Fuel inlet (From fuel filter) B: From supply pump to rail C: From rail to injector 1. Drive shaft 2. Supply pump drive gear (No. of teeth 31) 3. Pump holder 4. Supply pump a

D: To spill E: To fuel tank

5. High pressure pipe (Between pump and rail) 6. Fuel filter 7. Fuel injection pipe (No. 1) 8. Fuel injection pipe (No. 2)

9. Fuel injection pipe (No. 3) 10. Fuel injection pipe (No. 4) 11. Spill tube 12. Rail 13. Injector

When removing high-pressure pipe (5) and fuel injection pipes (7), (8), (9) and (10), apply a counter spanner to the connector on the supply pump (4) and injector (13) side.

95E-5 Series

11

SEN02127-00


Fuel injection nozzle

1

For direct fuel injection type

A: Fuel inlet (from supply pump) B: Fuel return (to fuel tank) 1. Backup ring 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

Specifications q Type: Bosch CRI2.0 injector q Injection pressure: 25.4 – 108 MPa {250 – 1,100 kg/cm2}

95E-5 Series


Fuel filter

SEN02127-00

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

SEN02127-00

Common rail

A: B: C: D: E: F:

From supply pump To No. 1 injector To No. 2 injector To No. 3 injector To No. 4 injector Fuel outlet when limiter is open

1. 2. 3. 4.

Common rail Pressure limiter Fuel pressure sensor HP connection

14


1

Structure q Common rail (1) distributes the high-pressure fuel from the high-pressure pump to the injectors of the cylinders. q Common rail (1) is equipped with fuel pressure sensor (3), HP connection (4), and pressure limiter (2). q The fuel injection pipes are connected to HP connection (4) to send the high-pressure fuel to the injectors. q The piping of the pressure limiter (2) is returned to the fuel tank.

95E-5 Series

SEN02127-00

Various sensor

16


1

95E-5 Series


1. 2. 3. 4. 5. 6. 7.

SEN02127-00

Camshaft speed sensor Crankshaft speed sensor Coolant temperature sensor Boost pressure/temperature sensor Oil pressure switch Common rail pressure sensor Atmospheric pressure sensor

95E-5 Series

17

SEN02127-00


Cooling system Cooling system diagram

1. 2. 3. 4. 5. 6. 7. 8.

18

1 1

Radiator Thermostat Water temperature gauge Water pump Water manifold Cylinder head Piston Cylinder block

95E-5 Series


Water pump

SEN02127-00

1

(With separate type water seal, bearing, integrated shaft)

a


A: B: C: D:

Water inlet (from radiator) Water inlet (from thermostat) Water outlet (to engine) Water outlet (to radiator)

1. 2. 3. 4. 5. 6.

Pump cover Impeller Water seal Pump body Boss Drive shaft

Specification q Type: Centrifugal type (V-belt drive)

95E-5 Series

19

SEN02127-00


Unit: mm No.

Check item

Criteria

1

Clearance of impeller body

Standard clearance: 0.3 – 2.0

2

Interference between shaft and fan pulley boss

Standard size

Remedy

Tolerance

Standard interference

Shaft

Hole

18

–0.000 –0.013

–0.066 –0.082

0.053 – 0.082

3

Interference between shaft and body

42

–0.000 –0.013

–0.025 –0.046

0.012 – 0.046 Replace

4

Interference between shaft and impeller

12

–0.000 –0.013

–0.035 –0.062

0.022 – 0.062

5

Curvature of shaft

6

Wear of seal ring of water seal

20

Repair limit: Runout at face (B): 0.1 Repair limit: Dimension (A): 0

95E-5 Series

SEN02127-00


Cooling fan drive and thermostat1

a


A: Direction of wind B: To radiator (coolant) C: From engine (coolant) a, b, c: Outside diameter of pulley d: Heater pickup port e: Thermo sensor f: Water temperature gauge pickup port

22

1. Fan 2. Fan belt 3. Water pump 4. Fan spacer 5. Fan pulley 6. Crankshaft pulley 7. Crankshaft 8. Thermostat case cover 9. Thermostat 10. Thermostat case 11. Alternator

95E-5 Series


SEN02127-00

Cooling fan drive

a


Outside diameter of pulley Unit: mm Engine

Machine model

SAA4D95LE-5


95E-5 Series

Fan

Alternator

Crankshaft pulley

a

b

c

189

76.1

170

23

SEN02127-00


Thermostat (with jiggle valve)

1. Piston 2. Case 3. Pellet 4. Seat 5. Valve 6. Case 7. Spring 8. Bypass spring 9. Bypass valve 10. Bypass seat 11. E-ring 12. Jiggle valve

24

a

Jiggle valve (12) allows air to flow but stops water from flowing to the top of thermostat. It allows the engine water temperature to rise in a short time.

95E-5 Series


SEN02127-00

Unit: mm No.

1

Check item

Thermostat

Criteria

Cracking temperature: 76 ± 2ºC Fully open: Shall open fully when immersed in hot water bath at Fully open temperature: 95ºC temperature between 95ºC and 77ºC for 4 – 5 minutes Replace Fully open lift: Min. 8

95E-5 Series

Remedy

(when immersed in hot water bath at 95ºC for 4 – 5 minutes)

25

SEN02127-00


Electrical equipment

1

Starting and charging system electrical circuit diagram

1

1. 2. 3. 4. 5. 6.

26

Battery Starting motor Alternator Starting switch Relay Electrical intake air heater

95E-5 Series


SEN02127-00

Alternator

1

Alternator with built-in regulator (Open type, 35A)

a 1. 2. 3. 4.

The shape is subject to machine models. Alternator (body) Alternator pulley Terminal B Internal connection diagram 4A. Alternator assembly 4B. IC regulator 4C. Terminal L load 4D. Starting switch 4E. Battery

Pulley Engine

SAA4D95LE-5

95E-5 Series


Type

Open type manufactured by NIHON DENSO

Specifications

Number of stage

Outside diameter (mm)

Weight (kg)

24 V, 35 A

1

76.1

4.7

27

SEN02127-00


Alternator mounting

a


a: Outside diameter of alternator pulley: 76.1 mm b: Outside diameter of crankshaft pulley: 170 mm 1. 2. 3. 4.

28

Alternator Nut (2 pieces) Adjustment rod V-belt

95E-5 Series


SEN02127-00

Starting motor

1

For 4.5 kW

a 1. 2. 3. 4. 5. 6. 7.

The shape is subject to machine models. Pinion gear Magnetic switch Starting motor assembly Jump start prohibition warning plate Jump start prevention cover 50 (terminal C) 30 (terminal B)

Engine SAA4D95LE-5

95E-5 Series


8. Internal connection diagram 8A. Relay 8B. Starting switch 8C. Battery 8D. 30 (terminal B) 8E. 50 (terminal C)

Type

Specifications

Number of pinion teeth

Weight (kg)

Drip proof, oil proof type manufactured by NIHON DENSO

24 V, 4.5 kW

11

8.5

29

SEN02127-00


Starting aid

1

Electric heater

a


1. Heater coil 2. Housing 3. Internal connection diagram

30

Specification Type of heater: Electrical intake air heater q Rated voltage: 22V (DC) q Load current: 110A

95E-5 Series


Engine controller

1. 2. 3. 4.

SEN02127-00

1

Controller body Engine wiring harness connector Machine wiring harness connector Electric power supply

Specifications Type CM2150

Dimensions A

B

C

D

277

218

61

60

95E-5 Series

Weight

Voltage

1,950kg 12V, 24V

31

SEN02127-00



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


1

Standard service value table for testing, adjusting, and troubleshooting

1

Air intake and exhaust system

Performance Category

Standard service value table

Body Lubrication system Cooling system

2

SAA4D95LE-5 PC138US-8, PC138USLC-8

Item

Speed

Measurement conditions

Unit

Standard value for new machine

Service limit value

Max. speed at no load

rpm

2,300 ± 60

2,300 ± 60

Min. speed at no load

rpm

1,100 ± 50

1,100 ± 50

Necessary speed for starting

At 0°C (without starting aid)

rpm

Min. 150

Min. 150

At –20°C (with starting aid)

rpm

Min. 100

Min. 100

Air intake resistance

Whole speed range

kPa {mmH2O}

Max. 3.73 {Max. 380}

7.47 {762}

Air boost pressure

At rated output

kPa {mmHg}

—

—

Exhaust pressure (Turbine inlet press.)

At rated output

kPa {mmHg}

—

—

Exhaust temperature (Turbine inlet temp.)

Whole speed range (20°C)

°C

Max. 650

700

At sudden acceleration (Low → High)

% (Bosch index)

Max. 30 (only engine side)

30 (only engine side)

At rated output

% (Bosch index)

Max. 15

35

At high idle

% (Bosch index)

Max. 10

20

Intake valve

mm

0.35

—

Exhaust gas color

Valve clearance (When engine is hot or cold)

a

Engine Machine model

Exhaust valve

mm

0.50

—

Min. 2.9 {Min. 30}

2.0 {20}

Compression pressure (SAE30 or SAE 15W-40)

Engine oil temperature: 40 – 60°C Engine speed: 320 – 360 rpm

MPa {kg/cm2}

Blow-by pressure (SAE30 or SAE 15W-40)

At rated output Engine coolant temperature: Min. 70°C

kPa {mmH2O}

Max. 0.59 {Max. 60}

0.98 {100}

At rated flywheel horsepower SAE30 or SAE15W-40 oil

MPa {kg/cm2}

0.34 – 0.61 {3.5 – 6.0}

0.25 {2.5}

MPa {kg/cm2}

0.29 – 0.49 {3.0 – 5.0}

0.21 {2.1}

MPa {kg/cm2}

Min. 0.18 {Min. 1.8}

0.15 {1.5}

MPa {kg/cm2}

Min. 0.15 {Min. 1.5}

0.13 {1.3}

Oil pressure (Oil temperature: Min. 80°C)

SAE 10W oil At low idling SAE30 or SAE15W-40 oil SAE 10W oil

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

Function of radiator pressure valve

Cracking pressure (Differential pressure)

MPa {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

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.

95E-5 Series


SEN02129-00

Running-in standard and performance test standard

1

Running-in standard Engine

SAA4D95LE-5

Machine model

PC138US-8, PC138USLC-8 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 a

This table shows the values when the fan is not installed. The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.

Performance test standard Engine

SAA4D95LE-5

Machine model


Test item

Rated output

Max. torque

72.1 kW/2,200 rpm (Gross) 358 Nm/1,500 rpm (Gross) {96.6 HP/2,200 rpm} (Gross) {36.5 kgm/1,500 rpm} (Gross)

Max. speed at no load

Min. speed at no load

2,300 ± 60 rpm

1,100 ± 50 rpm

Specification value (Gross value)

—

Speed

rpm

2,200 ± 5

1,500 ± 100

Dynamometer load

N {kg}

415 – 459 {42.3 – 46.8}

476 – 525 {48.5 – 53.5}

Output (Gross value)

kW {HP}

68.5 – 75.7 {91.8 – 101.5}

—

—

—

Torque (Gross value)

Nm {kgm}

—

340 – 376 {34.7 – 38.3}

—

—

Fuel consumption

sec/200cc

Coolant temperature

°C

80 – 95

80 – 95

80 – 95

80 – 95

Lubricating oil temperature

°C

90 – 110

90 – 110

90 – 110

80 – 110

Lubricating oil pressure

MPa {kg/cm2}

0.34 – 0.61 {3.5 – 6.0}

0.34 – 0.61 {3.5 – 6.0}

0.34 – 0.61 {3.5 – 6.0}

Min. 0.18 {Min. 1.8}

Exhaust temperature

°C

Max. 640

Max. 670

—

—

a a a a a a

The table gives the values under the standard condition (Atmospheric temperature: 25ºC, Atmospheric pressure: 99.9 kPa {750 mmHg}). Since the dynamometer loads, output, and torque in the table are measured with the fan removed, they are different from the specification values. 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). The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long. For fuel, use ASTM D975 No. 1 or No. 2. For lubricant, use SAE15W-40 or SAE30 oil.

95E-5 Series

3

SEN02129-00



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


Handling controller voltage circuit ................................................................................................................. 22

2

95E-5 Series


SEN02182-00

Testing and adjusting tools list Testing and adjusting item

Symbol

1

Part No.

Part name

Q'ty

Remarks

Testing exhaust temperature

A

799-101-1502 Digital thermometer

1

–99.9 – 1,299°C

Adjusting valve clearance

B

Commercially Clearance gauge available

1

Intake: 0.35 mm Exhaust: 0.50 mm

1 795-502-1590 Compression gauge

1

0 – 7 MPa {0 – 70 kg/cm2}

Testing compression pressure

C

Testing blow-by pressure

Testing oil pressure

795-471-1420 Adapter

1

6271-11-3880 Gasket

1

799-201-1504 Blow-by checker

1

0 – 5 kPa {0 – 500 mmH2O}

799-101-5002 Hydraulic tester

1

Pressure gauge: 2.5, 6, 40, 60 MPa {25, 60, 400, 600 kg/cm2}

790-261-1204 Digital hydraulic tester

1

Pressure gauge: 60 MPa {600 kg/cm2}

2 799-401-2320 Hydraulic tester

1


799-101-5002 Hydraulic tester

1

Pressure gauge: 2.5, 6, 40, 60 MPa {25, 60, 400, 600 kg/cm2}

790-261-1204 Digital hydraulic tester

1


1


795-471-1450 Adapter

1

8 × 1.25 mm o R1/8

07005-00812 Seal washer

1

2 D 1

E

1 Testing fuel pressure

F

2 799-201-2202 Boost gauge kit 3

1 6151-51-8490 Spacer

95E-5 Series

H

Inside diameter: 14 mm

2 6206-71-1770 Joint

1

Inside diameter of joint: 10 mm

3

07042-20108 Plug

1

PT1/8

Commercially Hose available

1

φ 15 mm x 2 – 3 m

Commercially Hose available

1

φ 5 mm x 2 – 3 m

6

Commercially Measuring cylinder available

1

7

Commercially Stopwatch available

1

799-601-4130 T-adapter

—

4 Testing leakage from pressure limiter and return G 5 rate from injector

Troubleshooting for controllers, sensors, and actuators

1

For 95E-5

For Ne sensor, Bkup sensor (Cam sensor)

799-601-4190 Socket

— For common rail pressure sensor

799-601-4240 Socket

— For atmospheric pressure sensor

799-601-4380 Socket

—

799-601-4160 T-adapter

— For lubricating oil pressure switch

795-799-5530 Socket

— For coolant temperature sensor

799-601-4340 Socket

— For supply pump IMV, injector

799-601-4260 T-adapter

— For controller (4-pole)

799-601-4220 T-adapter

—

For controller (60-pole: for engine terminal)

799-601-4390 Socket

—

For controller (60-pole: for chassis terminal)

For boost pressure and temperature sensor

799-601-9320 T-box

—

799-601-9310 Plate

—

799-601-4350 T-box

— For 60-pole type

For 24-pole type

3

SEN02182-00

Measuring intake air pressure q

4


1

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.

95E-5 Series


SEN02182-00

Testing exhaust temperature a

1

Run the engine and test the exhaust temperature in the whole speed range. a When testing with the engine mounted on the machine, test on the condition described in the shop manual for the machine.

5.

After finishing testing, remove the testing tools and return the removed parts.

Testing tools for exhaust temperature

Symbol

Part No.

A

799-101-1502

k

Part name Digital thermometer

a

Remove and install the testing tools after the exhaust manifold temperature has lowered. 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.

3.

4.

Install sensor [1] of digital thermometer A and connect it to thermometer [2].

95E-5 Series

5

SEN02182-00


Adjusting valve clearance a

Adjusting tools for valve clearance

Symbol

Part No.

B

Commercially available

Part name Clearance gauge

1.

Remove cylinder head covers (1).

2.

Rotate the crankshaft forward (clockwise seen from the front) and set wide notch (a) (Width: 25 mm) of signal plate (1) at the rear 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 "1.4TOP" (b) of front cover (2). Reference: All of the other notches of the signal plate are 5 mm in width. a Rotate the crankshaft with the crankshaft pulley bolt (3) (Width across flats: 27 mm). a Always rotate the crankshaft pulley bolt forward to prevent it from being loosened.

6

[Reference information when mounted on machine] q If plug (c) of the flywheel housing is removed, you can check the No. 1 cylinder top dead center mark (white paint) on the flywheel side. q You can install the barring tool for rotating the crankshaft by removing cover (d) of the flywheel housing. q For details, see the shop manual for the applicable machine.

1

a

3.

When the No. 1 cylinder is at the compression top dead center, the rocker arm of the No. 1 cylinder can be moved by the valve clearance with the hand. If the rocker arm cannot be moved, rotate the crankshaft one more turn.

Adjust the clearances of the valves marked with q in the valve arrangement drawing according to the following procedure.

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1) 2)

3)

While fixing adjustment screw (3), loosen locknut (4). Insert clearance gauge B in the clearance between rocker arm (5) and valve stem upper end (6) and adjust the valve clearance with adjustment screw (3). a With the clearance gauge inserted, turn the adjustment screw to a degree that you can move the clearance gauge lightly. a Valve clearance Intake valve: 0.35 ± 0.02 mm Exhaust valve: 0.50 ± 0.02 mm While fixing adjustment screw (3), tighten locknut (4). 3 Locknut: 39.2 – 49 Nm {4 – 5 kgm} a After tightening the locknut, check the valve clearance again.

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4.

Rotate the crankshaft forward by one turn to set the No. 4 cylinder to the compression top dead center and adjust the valve clearances marked with Q, similarly to the valves marked with q. Reference: You may rotate the crankshaft pulley by 180° and adjust the valve clearance of the cylinder which is set to the compression top dead center at this time (Firing order: 1 – 2 – 4 – 3).

5.

After finishing adjustment, return the removed parts. 3 Cylinder head cover mounting nut: 8.82 ± 0.98 Nm {0.9 ± 0.1 kgm}

7

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Testing compression pressure a

Testing tools for compression pressure

Symbol 1 C k

a

1.

2

Part No.

Part name

795-502-1590

Compression gauge

795-471-1420

Adapter

6271-11-3880

Gasket

When measuring the compression pressure, take care not to burn yourself on the exhaust manifold, muffler, etc. or get caught in a rotating part. Measure the compression pressure after the engine is warmed up (Engine oil temperature: 40 – 60°C).

2.

Insert adapter C2 in the injector mounting hole and fix it with holder (7). a Fit the gasket to the adapter end. 3 Holder mounting bolt: 27 – 30 Nm {2.8 – 3.1 kgm} a Seat the fulcrum of the holder perfectly before tightening the mounting bolts.

3.

Connect compression gauge C1 to adapter C2.

Remove the injector of the cylinder to be measured. a Measuring procedure for No. 1 cylinder is described below as an example. 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).

5)

8

1

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 terminal.

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4.

Connect the INSITE (bench test device) to the engine controller and set it in the no-injection cranking mode. q Instead of the above work, you may disconnect the wiring harness connectors from all the injectors so that fuel will not be injected at all. k Since starting of engine is dangerous, be sure to set the injectors so that they will not inject fuel before starting the check.

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3) 4)

5)

6) 5.

Crank the engine with the starting motor and measure the compression pressure. a Read the pressure when the gauge pointer is stabilized.

6.

After finishing measurement, remove the measuring instruments and return the removed parts according to the following procedure. 1) Install O-ring (8) and gasket (9) to injector (1). a Do not install O-ring (8) to groove "a".

2)

7)

Connect spill hose connector (6) to injector (1). Install high-pressure pipe (5). 3 High-pressure pipe flare nut (Both ends): 25.5 – 29.4 Nm {2.6 – 3.0 kgm} Install fuel scatter prevention cover (3) to the joint of high-pressure pipe (5). a Install fuel scatter prevention cover (3) with the slit down (on both injector side and common rail side). Install clamp (4) to high-pressure pipe (5). a Install the clamp to the position from which it was removed. (The mounting bolt goes through the clamp and enters the bolt hole of the air intake manifold. Accordingly, if the mounting bolt is installed normally, the clamp is installed to its original position.) Connect wiring harness connector (2) to injector (1).

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 perfectly before tightening the mounting bolts.

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9

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Testing blow-by pressure a

1

Testing tool for blow-by pressure

Symbol

Part No.

D

799-201-1504

Part name Blow-by checker

a

The test point is subject to machine models.

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 the machine, test on the condition described in the shop manual for the machine.

4.


10

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Testing oil pressure a

Testing tools for oil pressure

Symbol E

1

1 2

Part No. 799-101-5002

Part name Hydraulic tester

790-261-1204

Digital hydraulic tester

799-401-2320

Hydraulic tester

a

The test point is subject to machine models.

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.

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 the machine, test on the condition described in the shop manual for the machine.

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4.


11

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Handling fuel system parts a

a

12


1

Precautions for testing and maintaining fuel system The common rail fuel injection system (CRI) consists of more precise parts than the conventional fuel injection pump and nozzle. If foreign matter enters this system, it can cause a trouble. When testing and maintaining the fuel system, take care more than the past. If dust, etc. sticks to any part, wash that part thoroughly with clean fuel. Precautions for replacing fuel filter cartridge Be sure to use the Komatsu genuine fuel filter cartridge. Since the common rail fuel injection system (CRI) consists of more precise parts than the conventional fuel injection pump and nozzle, it employs a high-efficiency special filter to prevent foreign matter from entering it. If a filter other than the genuine one is used, the fuel system may have a trouble. Accordingly, never use such a filter.

Releasing residual pressure in fuel system a

a

a

k

1

Pressure is generated in the low-pressure circuit and high-pressure circuit of the fuel system while the engine is running. Low-pressure circuit: Feed pump – Fuel filter – Supply pump High-pressure circuit: Supply pump – Common rail – Injector The pressure in both low-pressure circuit and high-pressure circuit lowers to a safety level automatically 30 seconds after the engine is stopped. Before the fuel circuit is tested and its parts are removed, the residual pressure in the fuel circuit must be released completely. Accordingly, observe the following. Before testing the fuel system or removing its parts, wait at least 30 seconds after stopping the engine until the residual pressure in the fuel circuit is released. (Do not start the work just after stopping the engine since there is residual pressure.)

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Testing fuel pressure a

1 2 3

a k

1.

3.

Testing tools for fuel pressure

Symbol

F

1

Part No.

Part name

799-101-5002

Hydraulic tester

790-261-1204

Digital hydraulic tester

799-201-2202

Boost gauge kit

795-471-1450

Adapter

07005-00812

Seal washer

Engine speed

Fuel pressure

High idle

–49 – 0 kPa {–0.5 – 0 kg/cm2}

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

4.

2.

Run the engine at high idle and measure the fuel pressure. a If the fuel pressure is in the following range, it is normal. Reference: A value is negative pressure.

After finishing testing, remove the testing tools and return the removed parts. 3 Plug: 7.8 – 9.8 Nm {0.8 – 1.0 kgm}

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}

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13

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Reduced cylinder mode operation1

No-injection cranking

a

a

1. 2.

3.

14

Reduced cylinder mode operation means to run the engine with the fuel injectors of 1 or more cylinders disabled electrically to reduce the number of effective cylinders. The purposes and effects of this operation are as follows. This operation is used to find out a cylinder which does not output power normally (or, combustion in it is abnormal). When a cylinder is selected for the reduced cylinder mode operation, if the engine speed and output do not change from the normal operation (all-cylinder operation), that cylinder has 1 or more defects. The possible defects are as follows. 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 Since the common rail fuel injection system controls the injector of each cylinder electronically, the operator can perform the reduced cylinder mode operation easily with switches to find out a defective cylinder. a Perform the reduced cylinder mode operation 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).

q

a a

1

No-injection cranking means to crank the engine with the starting motor while all the injections are stopped electrically. The purpose and effect of this operation are as follows. Before the engine is started after it or the engine unit has been stored for a long period, the no-injection cranking is performed to lubricate the engine parts and protect them from seizure. Perform the no-injection operation with the engine mounted on the machine or connected to INSITE (bench test tool). Before performing, see "Testing method" in the shop manual for the machine or INSITE (bench test tool).

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Testing leakage from pressure limiter and return rate from injector a a

Insert spacer G1 on return block (3) side and tighten the removed joint bolt again. a Be sure to fit the gaskets to both ends of the spacer.

4)

Insert joint G2 on common rail (1) side and tighten the removed joint bolt again. a Be sure to fit the gaskets to both ends of the joint. Remove spill hose connector joint (5) and install plug G3. 3 Plug G3: 3.9 – 6.9 Nm {0.4 – 0.7 kgm}

1

The locations of the fuel circuit parts are subject to machine models. Testing tools for leakage from pressure limiter and return rate from injector

Symbol

G

3)

Part No.

Part name

1

6151-51-8490

Spacer

2

6206-71-1770

Joint

3

07042-20108

Plug

4


Hose

5


Hose

6


Measuring cylinder

7


Stopwatch

a

Prepare an oil pan of about 20 l to receive the fuel flowing out during the test.

1.

Preparation work 1) Remove spill hose (2) between common rail (1) and injector. 2) Remove tube (4) between common rail (1) and return block (3).

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5)

15

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6)

7)

8)

Connect test hose G4 to the end of joint G2. a Bind the connecting part of the test hose with a wire, etc. to prevent it from coming off. Connect test hose G5 to connector (6) side of spill hose (2). a Bind the connecting part of the test hose with a wire, etc. to prevent it from coming off.


2.

Testing leakage from pressure limiter 1) Lay test hose G4 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. q Or set the installed equipment 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 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 limiter is in the following range, it is normal. Leakage (cc/min)

At rated output

Max. 20

Reference: A limit value is the value mentioned above, but a standard value in normalcy is “0 cc/min. (no leak)”.

The above is the preparation work for testing.

5)

16

Engine speed (rpm)

After finishing testing, stop the engine.

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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 injector is in the following range, it is normal.

5) 4.

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Rated output speed (rpm)

Return (Spill) limit (cc/min)

1,600

190

1,700

200

1,800

210

1,900

220

2,000

230

After finishing testing, stop the engine.

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}

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17

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Bleeding air from fuel circuit

a a a

1.

18

1

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. The locations of the fuel circuit parts are subject to machine models. Fuel prefilter (1), priming pump (2) and air bleeding plug (3) on the fuel prefilter side are installed to the chassis. 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 add fuel through part (b) (holes around the central hole). a After filling the pre-fuel filter with fuel, remove the cap from part (a). a If clean fuel is not available, do not 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) externally.

2.

Install pre-fuel filter (1) to the filter head. a Apply engine oil thinly over the packing on the pre-fuel filter side. a After the packing of the pre-fuel filter touches the sealing face of the filter head, tighten the fuel filter 3/4 turns.

95E-5 Series


3.

Remove air bleeding plug (3) of the fuel prefilter 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.

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19

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Testing fuel system for leakage k

a


1

Very high pressure is generated in the highpressure circuit of the fuel system. If fuel leaks while the engine is running, it is dangerous since it can catch fire. After testing the fuel system or removing its parts, test it for fuel leakage according to the following procedure. Clean and degrease the engine and the parts around it in advance so that you can test it easily 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.

5.


6.

Run the engine at high idle.

7.


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

9.

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. a If no fuel leakage is detected, inspection is completed.

95E-5 Series


Testing and adjusting alternator belt tension

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1

Testing Press the intermediate point of the belt between alternator pulley and fan pulley with a finger and measure deflection (a) of the belt. a Pressing force: Approx. 58.8 N {Approx. 6 kg} a Deflection (a): 7 – 10 mm

95E-5 Series

Adjusting a If the deflection is out of the standard range, adjust it according to the following procedure. 1.

Loosen alternator fixing bolts (1) and (2). a Loosen fixing bolt (2) from the rear side of the engine.

2.

Adjust the tension of alternator belt (4) by turning adjustment bolt (3). a Do not loosen double nut (5) at the adjustment bolt end. (If you have loosened it, apply LOCTITE (LT-2) to it when tightening it.) Reference: If adjustment bolt (3) is tightened (turned to the right), al te rnato r b elt ( 4) is loo sened. If the former is turned to the left, the latter is tightened.

3.

After adjusting the belt tension, tighten alternator fixing bolts (1) and (2).

4.

Check again that the tension of alternator belt (4) is in the standard range.

21

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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

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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

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Points on troubleshooting k k k k k k

40 Troubleshooting

1

When troubleshooting a machine, stop it in a level ground, and check that the lock pin, chocks, and parking brake are securely fitted. 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. 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. Be extremely careful not to touch any hot parts or to get caught in any rotating parts. When disconnecting wiring, always disconnect the negative (–) terminal of the battery first. 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 connect it properly.

The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent reoccurrence of the failure. When carrying out troubleshooting, an important point is of course to understand 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 symptoms. 1.

2.

2

When carrying out troubleshooting, do not hurry to disassemble the components. If components are disassembled immediately after any failure occurs: q Parts that have no connection with the failure or other unnecessary parts will be disassembled. q It will become impossible to find the cause of the failure. It will also cause a waste of manhours, parts, or oil or grease, and at the same time, will also lose the confidence of the user or operator. For this reason, when carrying out troubleshooting, it is necessary to carry out thorough prior investigation and to carry out troubleshooting in accordance with the fixed procedure. Points to ask user or operator 1) Have any other problems occurred apart from the problem that has been reported? 2) Was there anything strange about the machine before the failure occurred? 3) Did the failure occur suddenly, or were there problems with the machine condition before this? 4) Under what conditions did the failure occur? 5) Had any repairs been carried out before the failure? When were these repairs carried out? 6) Has the same kind of failure occurred before?

3.

Check before troubleshooting 1) Check for symptoms of any abnormality in the machine and engine. 2) Be sure to check the CHECKS BEFORE STARTING items. 3) Check other inspection items, if necessary. 4) Some other maintenance items can be checked externally, so check any item that is considered to be necessary. 5) Check the controller for display of an error.

4.

Confirming failure Confirm the extent of the failure yourself, and judge whether to handle it as a real failure or as a problem with the method of operation, etc. a When operating the machine or engine to reenact the troubleshooting symptoms, do not carry out any investigation or measurement that may make the problem worse.

5.

Troubleshooting Use the results of the investigation and inspection in Items 2 – 4 to narrow down the causes of failure, then use the troubleshooting matrix to locate the position of the failure exactly. a The basic procedure for troubleshooting is as follows. 1) Start from the simple points. 2) Start from the most likely points. 3) Investigate other related parts or information.

95E-5 Series

40 Troubleshooting

6.

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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 investigate why the problem occurred. Then, remove the root cause.

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3

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40 Troubleshooting

Error code and failure code table

1

(for construction equipment)

4

INSITE error code

Machine failure code

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

Failure phenomenon

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

234

CA234

Eng. Overspeed

238

CA238

Ne Speed Sensor Sup. Volt. Error

271

CA271

IMV Short Error

272

CA272

IMV Open Error

322

CA322

Injector #1 (L/B #1) System Open/Short Error

324

CA324


331

CA331


332

CA332


351

CA351

INJ. Drive Circuit Error

352

CA352


386

CA386


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

689

CA689

Eng. Ne Speed Sensor Error

731

CA731

Eng. Bkup Speed Sensor Phase Error

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

Reference document No.

Troubleshooting of electrical system (E-mode), Part 1 SEN02185-00


95E-5 Series

40 Troubleshooting

a a

SEN02183-00

INSITE error code

Machine failure code

2249

CA2249

Rail Press. Very Low Error

2311

CA2311

Abnormality in IMV solenoid

2555

CA2555

Grid Heater Relay Volt. Low Error

2556

CA2556

Grid Heater Relay Volt. High Error

–

B@BAZG

Eng. Oil press. Torque Derate

–

B@BAZG

Eng. Oil press. Low Speed Derate

–

B@BCNS

Eng. Overheat

Failure phenomenon

Reference document No.


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. 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.

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5

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40 Troubleshooting

Information in troubleshooting table a

1

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 INSITE

Display on applicable machine

Contents of trouble

Trouble

Problem that appears on engine

Contents of trouble detected by engine controller

Action of controller

Action taken by engine controller to protect system or devices when engine controller detects trouble

Problem that appears on machine

Problem that appears on engine as result of action taken by engine controller (shown above)

Related information

Information related to detected trouble or troubleshooting

Causes

Standard value in normal state/Remarks on troubleshooting • Standard value in normal state to judge possible causes • Remarks on judgment

1

2 Possible causes and standard value in normal state

6

• 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 (24 V) circuit is in contact with power source (24 V) circuit. • Short circuit Independent wiring harnesses are in contact with each other abnormally.

Possible causes of trouble (Given numbers are reference numbers, which do not indicate (1) Method of indicating connector No. and handling of Tpriority) adapter Insert or connect T-adapter as explained below for troubleshooting, 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 specified. 4 • 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.

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40 Troubleshooting

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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/merging 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.

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ENGINE 1SHOP MANUAL

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40 Troubleshooting

1

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

SEN02185-00

40 Troubleshooting

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-20 Code [324/CA324] Injector #3 (L/B #3) System Open/Short Error ....................................................... 36 E-21 Code [331/CA331] Injector #2 (L/B #2) System Open/Short Error ....................................................... 38 E-22 Code [332/CA332] Injector #4 (L/B #4) System Open/Short Error ....................................................... 40 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

SEN02185-00

40 Troubleshooting

E-1 Code [111/CA111] ECM Critical Internal Failure Error code

Failure code

111

CA111

Contents of trouble Action of controller Problem that appears on machine Related information

Trouble

1

ECM Critical Internal Failure

• Abnormality occurred in controller. • None in particular. • Engine runs normally but it may stop during operation or may not be able to start. • Different machine models may have different connector Nos.

Cause 1 Defective fuse

Standard value in normal state/Remarks on troubleshooting Check fuse or circuit breaker on machine side directly for defect. (If fuse is broken or circuit breaker is turned OFF, circuit probably has ground fault.)

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective power supply cutout 2 relay Wiring harness between CE02 (female) Resis185 – (55) – (32) tance 265 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Possible causes and standard value in normal state Disconnection in wiring harness 3 (Disconnection in wiring or defective contact in connector)

4

Wiring harness between CE02 (female) (55) – R23 (1)

Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z

Wiring harness between CE03 (female) (1) – T12

Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z

Wiring harness between R23 (female) (3) – battery (+)

Resistance

Max. 1 z


Resistance

Max. 1 z

95E-5 Series

40 Troubleshooting

SEN02185-00

Cause

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Possible causes and standard value in normal state

4

Wiring harness between CE02 (female) (55) – R23 (1) and chassis ground

Resistance

Min. 1 Mz


Resistance

Min. 1 Mz


Resistance

Min. 1 Mz

Ground fault in wiring harness Wiring harness between CE02 (female) (Short circuit with GND circuit) (32) – R24 (2) and chassis ground

Resistance

Min. 1 Mz


Resistance

Min. 1 Mz


Resistance

Min. 1 Mz

Wiring harness between R23 (female) (3) – battery (+) and chassis ground

Resistance

Min. 1 Mz


Resistance

Min. 1 Mz

5 Defective engine controller

a Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. 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

SEN02185-00

40 Troubleshooting

Circuit diagram related to controller power supply (Case of PC128/138US-8)

6

95E-5 Series

40 Troubleshooting

SEN02185-00

E-2 Code [115/CA115] Eng. Ne and Bkup Speed Sensor Error Error code

Failure code

115

CA115

Contents of trouble Action of controller Problem that appears on machine

Trouble

1

Eng. Ne and Bkup Speed Sensor Error

• Abnormality occurred in Ne speed sensor circuit and Bkup speed sensor circuit simultaneously. • None in particular. • Engine cannot be started (if engine has been stopped). • Engine stops (if engine has been running).

Related information Causes


Standard value in normal state/Remarks on troubleshooting

1

Defective Ne speed sensor system

Carry out troubleshooting for code [689/CA689].

2

Defective Bkup speed sensor system

Carry out troubleshooting for code [778/CA778].

3

Defective mount of Ne speed sensor

Check mount of Ne speed sensor directly for defect (defective installation of sensor, internal of flywheel, etc.)

4

Defective mount of Bkup speed sensor

Check mount of Bkup speed sensor directly for defect (defective installation of sensor, internal of supply pump, etc.)

5

Defective connection (Wrong connection)

Check Ne speed sensor and Bkup speed sensor directly for defective connection (wrong connection).


If causes 1 – 5 are not detected, engine controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)

Reference: Bkup speed sensor = Cam speed sensor

95E-5 Series

7

SEN02185-00

40 Troubleshooting

E-3 Code [122/CA122] Charge Air Press Sensor High Error Error code

Failure code

122

CA122


Trouble

1

Charge Air Press Sensor High Error

• Signal voltage in charge pressure sensor circuit is abnormally high. • Fixes charge pressure (400 kPa {4.08 kg/cm2}) and continues operation. • Acceleration performance of engine drops. • Different machine models may have different connector Nos.

Causes 1


Defective sensor power supply If code [187/CA187] or [227/CA227] is indicated, carry out trousystem bleshooting for it first. Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting.

Defective charge pressure 2 sensor (Internal trouble)

PTIM Between (2) – (4)

Voltage Power supply

4.75 – 5.25 V

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. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.


Disconnection in wiring harness 3 (Disconnection in wiring or defective contact in connector)

Wiring harness between ENG1 (female) (19) – PTIM (female) (1)

Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG1 (female) (19) – PTIM (female) (1) and chassis ground

4

8

Resistance

Min. 1 Mz

Ground fault in wiring harness (Short circuit with GND circuit) Wiring harness between ENG1 (female) (36) – PTIM (female) (2) and chassis ground

Resistance

Min. 1 Mz

Wiring harness between ENG1 (female) (48) – PTIM (female) (4) and chassis ground

Resistance

Min. 1 Mz

95E-5 Series

40 Troubleshooting

SEN02185-00

Causes



5

Short circuit in wiring harness (With another wiring harness)


Wiring harness between ENG1 (female) (19) – PTIM (female) (1) and wiring harness between ENG1 (female) (36) – PTIM (female) (2)

Resistance

Min. 1 Mz

Wiring harness between ENG1 (female) (19) – PTIM (female) (1) and wiring harness between ENG1 (female) (48) – PTIM (female) (4)

Resistance

Min. 1 Mz

Chassis ground between ENG1 (female) (36) – PTIM (female) (2) and chassis ground between ENG1 (female) (48) – PTIM (female) (4)

Resistance

Min. 1 Mz

a Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. ENG1 Between (36) – (48)

Voltage Power supply

4.75 – 5.25 V

Circuit diagram related to charge pressure sensor

95E-5 Series

9

SEN02185-00

40 Troubleshooting

E-4 Code [123/CA123] Charge Air Press Sensor Low Error Error code

Failure code

123

CA123


Trouble

1

Charge Air Press Sensor Low Error

• Signal voltage in charge pressure sensor circuit is abnormally low. • Fixes charge pressure (400 kPa {4.08 kg/cm2}) and continues operation. • Acceleration performance of engine drops.

Related information Possible causes and standard value in normal state

10

Cause

Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for E-3 Code [122/CA122].

95E-5 Series

40 Troubleshooting

SEN02185-00

E-5 Code [131/CA131] Throttle Sensor High Error

1

Throttle sensor of accelerator pedal type Error code

Failure code

131

CA131


Trouble


• Signal voltage in throttle sensor circuit is abnormally high. • Sets throttle angle with signal other than throttle sensor signal and continues operation (depending on each model) • Different problems occur on different machine models.

Related information

(Since this code is not set for the related machines, details are not described.)

95E-5 Series

11

SEN02185-00

40 Troubleshooting

Throttle sensor of fuel control dial type (Case of PC128/138US-8) Error code

Failure code

131

CA131


Trouble


• Signal voltage in throttle sensor circuit is abnormally high. • Sets throttle angle with signal other than throttle sensor signal and continues operation (depending on each model) • Different problems occur on different machine models. • Different machine models may have different connector Nos.

Causes


Defective sensor power supply If code [2185/CA2185] or [2186/CA2186] is indicated, carry out 1 system troubleshooting for it first. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 2

Defective fuel control dial (Internal trouble)

P20 (male)

Resistance

Between (1) – (3)

4.0 – 6.0 kz

Between (2) – (1)

0.25 – 5.0 kz

Between (2) – (3)

0.25 – 5.0 kz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.



Wiring harness between CE2 (female) (27) – P20 (female) (1)

Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between CE2 (female) (27) Ground fault in wiring harness – P20 (female) (1) and chassis ground 4 (Short circuit with GND circuit) Wiring harness between CE2 (female) (35) – P20 (female) (2) and chassis ground

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

Wiring harness between CE2 (female) (28) – P20 (female) (3) and chassis ground

Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 5 Defective engine controller

12

CE2

Voltage

Between (27) – (28)

Power supply

4.75 – 5.25 V

Between (35) – (28)

Signal

0.5 – 4.5 V

95E-5 Series

40 Troubleshooting

SEN02185-00

Circuit diagram related to throttle sensor of fuel control dial type (Case of PC128-138US-8)

95E-5 Series

13

SEN02185-00

40 Troubleshooting

E-6 Code [132/CA132] Throttle Sensor Low Error Error code

Failure code

132

CA132


Trouble

1

Throttle Sensor Low Error

• Signal voltage in throttle sensor circuit is abnormally low. • Sets throttle angle with signal other than throttle signal and continues operation (depending on each model). • Different problems occur on different machine models.


14

Cause


95E-5 Series

40 Troubleshooting

SEN02185-00

E-7 Code [144/CA144] Coolant Temp. Sensor High Error Error code

Failure code

144

CA144

Contents of trouble Action of controller

Trouble

1

Coolant Temp. Sensor High Error

• Signal voltage in coolant temperature sensor circuit is abnormally high. • Fixes coolant temperature (90°C) and continues operation.

Problem that appears on machine Related information

• Different machine models may have different connector Nos.

Cause Defective coolant temperature 1 sensor (Internal trouble)


Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. TWTR (male)

Coolant temperature

Resistance

Between (1) – (2)

10 – 100°C

0.6 – 20 kz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring Wiring harness between ENG1 (female) Resis2 Max. 1 z or defective contact in connec- (47) – TWTR (female) (1) tance tor) Wiring harness between ENG1 (female) ResisMax. 1 z (49) – TWTR (female) (2) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

3

Ground fault in wiring harness (Short circuit with GND circuit) Wiring harness between ENG1 (female) (47) – TWTR (female) (1) and chassis ground


Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ENG1 (female)

Coolant temperature

Resistance

Between (47) – (49)

10 – 100°C

0.6 – 20 kz

Circuit diagram related to coolant temperature sensor

95E-5 Series

15

SEN02185-00

40 Troubleshooting

E-8 Code [145/CA145] Coolant Temp. Sensor Low Error Error code

Failure code

145

CA145


Trouble

1

Coolant Temp. Sensor Low Error

• Signal voltage in coolant temperature sensor circuit is abnormally low. • Fixes coolant temperature (90°C) and continues operation.

Problem that appears on machine Related information Possible causes and standard value in normal state

16

Cause

Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting E-7 Code [144/CA144].

95E-5 Series

SEN02185-00

40 Troubleshooting

E-9 Code [153/CA153] Charge Air Temp. Sensor High Error Error code

Failure code

153

CA153


Trouble

1

Charge Air Temp. Sensor High Error

• Signal voltage in charge temperature sensor circuit is abnormally high. • Fixes charge temperature (intake air temperature) (70°C) and continues operation.



Cause


1

Defective charge temperature sensor (Internal trouble)

PTIM (male)

Intake air temperature

Resistance

Between (3) – (4)

10 – 100°C

0.5 – 20 kz

Between (3) – chassis ground

All range

Min. 1 Mz



Disconnection in wiring harness Wiring harness between ENG1 (female) 2 (Disconnection in wiring or (11) – PTIM (female) (3) defective contact in connector) Wiring harness between ENG1 (female) (48) – PTIM (female) (4)

Resistance

Max. 1 z

Resistance

Max. 1 z


3

Ground fault in wiring harness (Short circuit with GND circuit) Wiring harness between ENG1 (female) (11) – PTIM (female) (3) and chassis ground

Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4 Defective engine controller

18

ENG1 (female)

Intake air temperature

Resistance

Between (11) – (48)

10 – 100°C

0.5 – 20 kz

95E-5 Series

40 Troubleshooting

SEN02185-00

Circuit diagram related to charge temperature sensor

95E-5 Series

19

SEN02185-00

40 Troubleshooting

E-10 Code [154/CA154] Charge Air Temp. Sensor Low Error Error code

Failure code

154

CA154


Trouble

1

Charge Air Temp. Sensor Low Error

• Signal voltage in charge temperature sensor circuit is abnormally low. • Fixes charge temperature (intake air temperature) (70°C) and continues operation.


20

Cause


95E-5 Series

40 Troubleshooting

SEN02185-00

E-11 Code [187/CA187] Sensor Sup. 2 Volt. Low Error Error code

Failure code

187

CA187


Trouble

1


• Signal voltage in sensor power supply 2 (5 V) circuit is abnormally low. • Operates Bkup speed sensor with signals of Ne speed sensor. • Sets atmospheric pressure sensor to default value (52.44 kPa {0.53 kg/cm2}) and continues operation. • Fixes charge pressure sensor value (400 kPa {4.08 kg/cm2}) and continues operation. • Output drops.


Causes



95E-5 Series

21

SEN02185-00

40 Troubleshooting

E-12 Code [221/CA221] Ambient Air Press. Sensor High Error Error code

Failure code

221

CA221


Trouble

1

Ambient Air Press. Sensor High Error

• Signal voltage in atmospheric pressure sensor circuit is abnormally high. • Sets atmospheric pressure sensor to default value (52.44 kPa {0.53 kg/cm2}) and continues operation. • Output drops. • Different machine models may have different connector Nos.

Causes 1


Defective sensor power supply If code [187/CA187] or [227/CA227] is indicated, carry out trousystem bleshooting for it first. a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.

Defective atmospheric pres2 sure sensor (Internal trouble)

PAMB

Voltage

Between (1) – (3)

Power supply

4.75 – 5.25 V

Between (2) – (3)

Signal

0.3 – 4.7 V

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. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Possible causes and standard value in normal state


Wiring harness between ENG1 (female) (36) – PAMB (female) (1)

Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG1 (female) (36) – PAMB (female) (1) and chassis ground

4

22

Resistance

Min. 1 Mz

Ground fault in wiring harness (Short circuit with GND circuit) Wiring harness between ENG1 (female) (20) – PAMB (female) (2) and chassis ground

Resistance

Min. 1 Mz

Wiring harness between ENG1 (female) (48) – PAMB (female) (3) and chassis ground

Resistance

Min. 1 Mz

95E-5 Series

40 Troubleshooting

SEN02185-00

Causes




Wiring harness between ENG1 (female) (36) – PAMB (female) (1) and wiring harness between ENG1 (female) (20) – PAMB (female) (2)

Resistance

Min. 1 Mz


Resistance

Min. 1 Mz


Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. 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

SEN02185-00

40 Troubleshooting

E-13 Code [222/CA222] Ambient Air Press. Sensor Low Error Error code

Failure code

222

CA222


Trouble

1

Ambient Air Press. Sensor Low Error

• Signal voltage in atmospheric pressure sensor circuit is abnormally low. • Sets oil pressure to default value (52.44 kPa {0.53 kg/cm2}) and continues operation. • Output drops.


24

Causes


95E-5 Series

40 Troubleshooting

SEN02185-00

E-14 Code [227/CA227] Sensor Sup. 2 Volt. High Error Error code

Failure code

227

CA227


Trouble

1


• Signal voltage in sensor power supply 2 (5 V) circuit is abnormally high. • Operates Bkup speed sensor with signals of Ne speed sensor. • Sets atmospheric pressure sensor to default value (52.44 kPa {0.53 kg/cm2}) and continues operation. • Fixes charge pressure sensor value (400 kPa {4.08 kg/cm2}) and continues operation. • Output drops. • Different machine models may have different connector Nos.

Causes 1 Defective related system

Standard value in normal state/Remarks on troubleshooting If another failure code is indicated, carry out troubleshooting for it. a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.

Disconnect devices Defective sensor (Internal trou- at right in order. If 2 error code disapble) pears when a device is disconnected, that device has a defect in it.

Bkup speed sensor

CAM connector

Atmospheric pressure sensor

PAMB connector

Charge pressure sensor

PTIM connector



Disconnection in wiring harness Wiring harness between ENG1 (female) 3 (Disconnection in wiring or (36) – each sensor (female) defective contact in connector) Wiring harness between ENG1 (female) (48) – each sensor (female)

Resistance

Max. 1 z

Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG1 (female) Ground fault in wiring harness (36) – each sensor (female) and chassis 4 (Short circuit with GND circuit) ground

Resistance

Min. 1 Mz

Wiring harness between ENG1 (female) (48) – each sensor (female) and chassis ground

Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 5

6


Defective engine controller

Wiring harness between ENG1 (female) (36) – each sensor (female) and Wiring harness between ENG1 (female) (48) – each sensor (female)

Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. ENG1

Voltage

Between (36) – (48)

4.75 – 5.25V

Reference: Bkup speed sensor = Cam speed sensor 95E-5 Series

25

SEN02185-00

40 Troubleshooting

Circuit diagram related to sensor power supply 2 (5 V)

26

95E-5 Series

40 Troubleshooting

SEN02185-00

E-15 Code [234/CA234] Eng. Overspeed Error code

Failure code

234

CA234


Trouble

1

Eng. Overspeed

• Engine speed is above operating range. • Limits fuel injection rate until engine speed lowers to operating range. • Engine speed fluctuates.

Related information Cause Possible causes and standard value in normal state

95E-5 Series


1 Defective related system

If another failure code is indicated, carry out troubleshooting for it.

2 Improper way of use

Way of use may be improper. Teach proper way of use to operator.


If causes 1 and 2 are not detected, engine controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)

27

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40 Troubleshooting

E-16 Code [238/CA238] Ne Speed Sensor Sup. Volt. Error Error code

Failure code

238

CA238


Trouble

1

Ne Speed Sensor Sup. Volt. Error

• Abnormality occurred in Ne speed sensor power supply (5 V) circuit. • Controls Ne speed sensor with signals of Bkup speed sensor. • Running engine stops (when Bkup speed sensor is also abnormal). • Stopped engine cannot be started (when Bkup speed sensor is also abnormal). • Different machine models may have different connector Nos.

Cause


1

Defective Ne speed sensor (Internal trouble)

Disconnect devices at right in order. If error code disappears when a device is disconnected, that device has a defect in it.

Ne speed sensor

NE connector



Disconnection in wiring harness (Disconnection in wiring Wiring harness between ENG1 (female) 2 or defective contact in connec- (26) – NE (female) (1) tor) Wiring harness between ENG1 (female) (44) – NE (female) (2)

Resistance

Max. 1 z

Resistance

Max. 1 z


4

Ground fault in wiring harness Wiring harness between ENG1 (female) (Short circuit with GND circuit) (26) – NE (female) (1) and chassis ground

Resistance

Min. 1 Mz

Wiring harness between ENG1 (female) (44) – NE (female) (2) and chassis ground

Resistance

Min. 1 Mz

Short circuit in wiring harness (with another wiring harness)


a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG1 (female) (26) – NE (female) (1) and between ENG1 (female) (44) – NE (female) (2)

Resistance

Min. 1 Mz


Voltage

Between (26) – (44)

4.75 – 5.25 V


28

95E-5 Series

40 Troubleshooting

SEN02185-00

Circuit diagram related to Ne speed sensor power supply

95E-5 Series

29

SEN02185-00

40 Troubleshooting

E-17 Code [271/CA271] IMV Short Error Error code

Failure code

271

CA271


Trouble

1

IMV Short Error

• There is short circuit in IMV circuit of supply pump. • None in particular.



Causes


1

Defective supply pump IMV (Internal trouble)

PREG (male)

Resistance

Between (1) – (2)

2.3 – 5.3 z

Between (1), (2) – chassis ground

Min. 1 Mz


Ground fault in wiring harness Wiring harness between ENG1 (female) (Short circuit with GND circuit) (10) – PREG (female) (2)

Resistance

Min. 1 Mz

Wiring harness between ENG1 (female) (14) – PREG (female) (1)

Resistance

Min. 1 Mz


a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Short circuit with 3 24V circuit) in wiring harness

Wiring harness between ENG1 (female) (10) – PREG (female) (2) and chassis ground

Voltage

Max. 1V


Voltage

Max. 1V


30


ENG1 (female)

Resistance

Between (10) – (14)

2.3 – 5.3 z


Min. 1 Mz

95E-5 Series

40 Troubleshooting

SEN02185-00

Circuit diagram related to supply pump IMV

95E-5 Series

31

SEN02185-00

40 Troubleshooting

E-18 Code [272/CA272] IMV Open Error Error code

Failure code

272

CA272


Trouble

1

IMV Open Error

• There is disconnection in IMV circuit of supply pump. • None in particular.



Causes


1

Defective supply pump IMV (Internal disconnection)

PREG (male)

Resistance

Between (1) – (2)

2.3 – 5.3 z


Min. 1 Mz



Disconnection in wiring harness Wiring harness between ENG1 (female) 2 (Disconnection in wiring or (10) – PREG (female) (2) defective contact in connector) Wiring harness between ENG1 (female) (14) – PREG (female) (1)

Resistance

Max. 1 z

Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG1 (female) Ground fault in wiring harness (10) – PREG (female) (2) and chassis 3 (Short circuit with GND circuit) ground

Resistance

Min. 1 Mz


Resistance

Min. 1 Mz


32


ENG1 (female)

Resistance

Between (10) – (14)

2.3 – 5.3 z

Between (10) (14) – chassis ground

Min. 1 Mz

95E-5 Series

40 Troubleshooting

SEN02185-00

Circuit diagram related to supply pump IMV

95E-5 Series

33

SEN02185-00

40 Troubleshooting

E-19 Code [322/CA322] Injector #1 (L/B #1) System Open/Short Error 1 Error code

Failure code

322

CA322


Trouble


• There is disconnection or short circuit in injector #1 circuit. • None in particular. • Output drops. • Rotation is unstable. • Different machine models may have different connector Nos.

Causes


1

Defective injector #1 (Internal trouble)

CN1 (male)

Resistance

Between (1) – (2)

0.4 – 1.1 z


Min. 1 Mz



Disconnection in wiring harness Wiring harness between ENG1 (female) 2 (Disconnection in wiring or (57) – CN1 (female) (1) defective contact in connector) Wiring harness between ENG1 (female) (53) – CN1 (female) (2)

Resistance

Max. 1 z

Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG1 (female) Ground fault in wiring harness (57) – CN1 (female) (1) and chassis 3 (Short circuit with GND circuit) ground

Resistance

Min. 1 Mz

Wiring harness between ENG1 (female) (53) – CN1 (female) (2) and chassis ground

Resistance

Min. 1 Mz

4

Defective injector or wiring har- If another failure code for injector abnormality is displayed, carry ness of another cylinder out troubleshooting for it. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

5

34


ENG1 (female)

Resistance

Between (57) – (53)

0.4 – 1.1 z


Min. 1 Mz

95E-5 Series

40 Troubleshooting

SEN02185-00

Circuit diagram related to injector #1

95E-5 Series

35

SEN02185-00

40 Troubleshooting


Failure code

324

CA324


Trouble



Cause


1


CN3 (male)

Resistance

Between (1) – (2)

0.4 – 1.1 z


Min. 1 Mz



Disconnection in wiring harness (Disconnection in wiring Wiring harness between ENG1 (female) 2 or defective contact in connec- (55) – CN3 (female) (1) tor) Wiring harness between ENG1 (female) (59) – CN3 (female) (2)

Resistance

Max. 1 z

Resistance

Max. 1 z


Resistance

Min. 1 Mz


Resistance

Min. 1 Mz

4



36

ENG1 (female)

Resistance

Between (55) – (59)

0.4 – 1.1 z


Min. 1 Mz

95E-5 Series

40 Troubleshooting

SEN02185-00


95E-5 Series

37

SEN02185-00

40 Troubleshooting


Failure code

331

CA331


Trouble



Cause


1


CN2 (male)

Resistance

Between (1) – (2)

0.4 – 1.1 z


Min. 1 Mz




Resistance

Max. 1 z

Resistance

Max. 1 z


Resistance

Min. 1 Mz


Resistance

Min. 1 Mz

4



38

ENG1 (female)

Resistance

Between (45) – (58)

0.4 – 1.1 z


Min. 1 Mz

95E-5 Series

40 Troubleshooting

SEN02185-00


95E-5 Series

39

SEN02185-00

40 Troubleshooting


Failure code

332

CA332


Trouble



Cause


1


CN4 (male)

Resistance

Between (1) – (2)

0.4 – 1.1 z


Min. 1 Mz




Resistance

Max. 1 z

Resistance

Max. 1 z


Resistance

Min. 1 Mz


Resistance

Min. 1 Mz

4



40

ENG1 (female)

Resistance

Between (56) – (51)

0.4 – 1.1 z


Min. 1 Mz

95E-5 Series

40 Troubleshooting

SEN02185-00


95E-5 Series

41

SEN02185-00

40 Troubleshooting

E-23 Code [351/CA351] INJ. Drive Circuit Error Error code

Failure code

351

CA351


Trouble

1

INJ. Drive Circuit Error

• Abnormality occurred in injector drive circuit. • Limits output and continues operation (Limits common rail pressure). • Output drops. • Different machine models may have different connector Nos.

Cause



If another failure code (code of abnormality in injector system) is indicated, carry out troubleshooting for it.

2 Defective fuse

Check fuse or circuit breaker on machine side directly for defect. (If fuse is broken or circuit breaker is turned OFF, circuit probably has ground fault.)

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective power supply cutout 3 relay Wiring harness between CF02 (female) Resis185 – (55) – (32) tance 265 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Possible causes and standard value in normal state Disconnection in wiring harness 4 (Disconnection in wiring or defective contact in connector)

42

Wiring harness between CF02 (female) (55) – R23 (1)

Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z

Wiring harness between CF03 (female) (1) – T12

Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z

95E-5 Series

40 Troubleshooting

SEN02185-00

Cause



5

Wiring harness between CF02 (female) (55) – R23 (1) and chassis ground

Resistance

Min. 1 Mz


Resistance

Min. 1 Mz


Resistance

Min. 1 Mz

Ground fault in wiring harness Wiring harness between CF02 (female) (Short circuit with GND circuit) (32) – R24 (2) and chassis ground

Resistance

Min. 1 Mz


Resistance

Min. 1 Mz


Resistance

Min. 1 Mz


Resistance

Min. 1 Mz


Resistance

Min. 1 Mz


95E-5 Series

a Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. CF03

Voltage

Between (3) – (1)

20 – 30 V

43

SEN02185-00

40 Troubleshooting

Circuit diagram related to controller power supply (case of PC128/138US-8)

44

95E-5 Series

40 Troubleshooting

SEN02185-00

E-24 Code [352/CA352] Sensor Sup. 1 Volt. Low Error Error code

Failure code

352

CA352


Trouble

1


• Signal voltage in sensor power supply 1 (5 V) circuit is abnormally low. • Limits output of common rail pressure sensor and continues operation (Limits common rail pressure). • Output drops.


95E-5 Series

Causes


45

SEN02185-00

40 Troubleshooting

E-25 Code [386/CA386] Sensor Sup. 1 Volt. High Error Error code

Failure code

386

CA386


Trouble

1


• Signal voltage in sensor power supply 1 (5 V) circuit is abnormally high. • Limits output of common rail pressure sensor and continues operation (Limits common rail pressure). • Output drops. • Different machine models may have different connector Nos.

Causes 1 Defective related system

Standard value in normal state/Remarks on troubleshooting If another failure code is indicated, carry out troubleshooting for it. a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.

Disconnect devices Defective sensor (Internal trou- at right in order. If 2 error code disapble) pears when a device is disconnected, that device has a defect in it.

Common rail pressure sensor

PFUEL connector



Disconnection in wiring harness Wiring harness between ENG1 (female) 3 (Disconnection in wiring or (36) – PFUEL (female) (1) defective contact in connector) Wiring harness between ENG1 (female) (48) – PFUEL (female) (3)

Resistance

Max. 1 z

Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG1 (female) Ground fault in wiring harness (36) – PFUEL (female) (1) and chassis 4 (Short circuit with GND circuit) ground

Resistance

Min. 1 Mz

Wiring harness between CE01 (female) (48) – PFUEL (female) (3) and chassis ground

Resistance

Min. 1 Mz


6

46



Wiring harness between ENG1 (female) (36) – PFUEL (female) (1) and wiring harness between ENG1 (female) (48) – PFUEL (female) (3)

Resistance

Min. 1 Mz


Voltage

Between (36) – (48)

4.75 – 5.25V

95E-5 Series

40 Troubleshooting

SEN02185-00

Circuit diagram related to sensor power supply 1 (5 V)

95E-5 Series

47

SEN02185-00

40 Troubleshooting

E-26 Code [431/CA431] Idle Validation SW Low error

1


Failure code

431

CA431


Trouble

Idle Validation SW Low error

• Abnormality occurred in idle validation switch circuit • Sets throttle angle to certain value and continues operation (depending on each model).



E-27 Code [432/CA432] Idle Validation Process error Error code

Failure code

432

CA432


Trouble

1

Idle Validation Process error

• Abnormality occurred in processing of idle validation switch circuit. • Sets throttle angle to certain value and continues operation (depending on each model).


48

Cause


95E-5 Series

40 Troubleshooting

SEN02185-00

E-28 Code [435/CA435] Abnormality in engine oil pressure switch Error code

Failure code

435

CA435


Trouble

1

Abnormality in engine oil pressure switch

• Abnormality occurred in engine oil pressure switch signal circuit. • None in particular. • Engine oil pressure switch-based engine protection function does not function.



a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective engine oil pressure 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 Resisdefective contact in connec- Wiring harness between ENG1 (female) (32) Max. 1 z – POIL (female) (1) tance tor) a Troubleshoot with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3

Short circuit in wiring harness Wiring harness among all pins between (With another wiring harness) ENG1 (female) (32) – ENG1 (female) (With all connectors of wiring harness disconnected)


Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ENG1 (Female)

Resistance


Max. 1 z

Circuit diagram related to engine oil switch

95E-5 Series

49

SEN02185-00

40 Troubleshooting

E-29 Code [441/CA441] Battery voltage low error Error code

Failure code

441

CA441


Trouble

1

Battery voltage low error

• Power supply voltage is abnormally low. • None in particular. • Engine continues operation normally, but it may stop during operation or may not be able to start.


Cause


E-30 Code [442/CA442] Battery voltage high error Error code

Failure code

442

CA442


Trouble

1

Battery voltage high error

• Power supply voltage is abnormally high. • None in particular. • Engine continues operation normally, but it may stop during operation or may not be able to start.


50

Cause


95E-5 Series

SEN02185-00



52

SEN02186-00

ENGINE 1SHOP MANUAL

95E-5 Series

40 Troubleshooting

1

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

SEN02186-00

40 Troubleshooting

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

40 Troubleshooting

SEN02186-00

E-31 Code [449/CA449] Rail Press. Very High Error Error code

Failure code

449

CA449


Trouble

1

Rail Press. Very High Error

• Common rail pressure sensor circuit detected abnormally high pressure (level 2). • Limits output and continues operation (Limits common rail pressure). • Output drops.


95E-5 Series

Causes


3

SEN02186-00

40 Troubleshooting

E-32 Code [451/CA451] Rail Press. Sensor High Error Error code

Failure code

451

CA451


Trouble

1

Rail Press. Sensor High Error

• Signal voltage in common rail pressure sensor circuit is abnormally high. • Limits output and continues operation (Limits common rail pressure). • Output drops. • Different machine models may have different connector Nos.

Causes 1


Defective sensor power supply If code [352/CA352] or [386/CA386] is indicated, carry out trousystem bleshooting for it first. a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting.

Defective common rail pres2 sure sensor (Internal trouble)

PFUEL

Voltage

Between (1) – (3)

Power supply

4.75 – 5.25 V

Between (2) – (3)

Signal

0.25 – 4.6 V

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. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Possible causes and standard value in normal state


Wiring harness between ENG1 (female) (36) – PFUEL (female) (1)

Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG1 (female) (36) – PFUEL (female) (1) and chassis ground

4

4

Resistance

Min. 1 Mz

Ground fault in wiring harness (Short circuit with GND circuit) Wiring harness between ENG1 (female) (29) – PFUEL (female) (2) and chassis ground

Resistance

Min. 1 Mz

Wiring harness between ENG1 (female) (48) – PFUEL (female) (3) and chassis ground

Resistance

Min. 1 Mz

95E-5 Series

40 Troubleshooting

SEN02186-00

Causes





Resistance

Min. 1 Mz


Resistance

Min. 1 Mz

Wiring harness between ENG1 (female) (29) – PFUEL (female) (2) and wiring harness between ENG (female) (48) – PFUEL (female) (3)

Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. 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

SEN02186-00

40 Troubleshooting

E-33 Code [452/CA452] Rail Press. Sensor Low Error Error code

Failure code

452

CA452


Trouble

1

Rail Press. Sensor Low Error

• Signal voltage in common rail pressure sensor circuit is abnormally low. • Limits output and continues operation (Limits common rail pressure). • Output drops.


6

Cause


95E-5 Series

40 Troubleshooting

SEN02186-00

E-34 Code [553/CA553] Rail Press. High Error Error code

Failure code

553

CA553


Trouble

1

Rail Press. High Error

• Common rail pressure sensor circuit detected abnormally high pressure (level 1). • None in particular. • Output drops.



95E-5 Series




2 Use of improper fuel

Check fuel used directly (for high viscosity).

3

Defective electrical system of common rail pressure sensor

Common rail pressure sensor may have electric trouble. Carry out troubleshooting for code [451/CA451] (E-32).

Defective mechanical system 4 of common rail pressure sensor

Check mechanical system of common rail pressure sensor directly.

5 Defective overflow valve

Check overflow valve directly for broken spring, worn seat, and stuck ball.

6 Clogging of overflow piping

Check overflow piping directly for clogging.

7 Defective pressure limiter

Check pressure limiter directly for mechanical defect.

7

SEN02186-00

40 Troubleshooting

E-35 Code [559/CA559] Rail Press. Low Error Error code

Failure code

559

CA559


Trouble

1

Rail Press. Low Error

• Supply pump does not feed fuel (level 1). • Limits common rail pressure. • Output drops.






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 pressure in fuel low-pressure circuit, see Testing and adjusting, "Testing fuel pressure".

4

Defective low-pressure circuit device

5

Defective electrical system of supply pump EMV

Supply pump EMV may have electric trouble. Carry out troubleshooting for following codes [271/CA271] (E-17), [272/CA272] (E-18).

6

Defective common rail pressure sensor

Common rail pressure sensor may be defective. Check wiring harness for damage.

7 Defective pressure limiter

Pressure in fuel low-pressure circuit Min. 0.15 MPa {Min. 1.5 kg/cm2} (At high idle or rated (stall) load)

a For testing of leakage from pressure limiter, see Testing and adjusting, "Testing leakage from pressure limiter and return rate from injector". Leakage from pressure limiter (At stall load)

Max. 10 cc/min

a For testing of return rate (spill) from injector, see Testing and adjusting, "Testing leakage from pressure limiter and return rate from injector".

8 Defective injector

9 Defective supply pump

Speed at rated operation (at stall)

Return (Spill) limit from 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

If causes 1 – 8 are not detected, supply pump may be defective.

Carry out the above troubleshooting and take a record of the contents of the attached “Check sheet for nopressure feed“.

8

95E-5 Series

40 Troubleshooting

SEN02186-00

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

SEN02186-00

40 Troubleshooting

Check sheet for no-pressure feed Model Machine serial No. Engine Engine serial No.

Work No. Date of check Service meter Worker's name

# #

/

/ h

A. Visual check 1 Fuel leakage to outside 2 Clogging of fuel tank breather

Good NG

B. Check with machine monitor (Fault history function, monitoring function, and reduced cylinder mode function) 3 Check of error/failure code / / / / Check of monitoring information Standard value Code Displayed item Checking condition Unit Measured value (Reference value) Low idle rpm *1 Engine speed High idle rpm Equivalent to rating rpm Low idle % 0 *2 Throttle opening High idle % 100 *3 Fuel injection command Equivalent to rating mm3 — Common rail pressure 4 *4 Equivalent to rating MPa command Common rail fuel *5 Equivalent to rating MPa pressure Low idle CA — Fuel injection timing *6 High idle CA — command Equivalent to rating CA — *7 Boost pressure Equivalent to rating 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 (Reference value) No. 1 cylinder Low idle rpm — 5 No. 2 cylinder Low idle rpm — *10 No. 3 cylinder Low idle rpm — No. 4 cylinder Low idle rpm —

Good NG

C. Check of fuel circuit pressure 6

Checking condition

Fuel low-pressure circuit pressure High idle or rated (stall) load

Unit

Standard value (Reference value)

MPa {kg/cm2}

Min. 0.15 {Min. 1.5}

Measured value

D. Check of strainers and filters 7 Visual check of fuel filter E.Check of leakage and return rate 8

9

10

Leakage through pressure limiter

Return rate from injector

Good NG

—

—

— — — —

— — — —

—

—

—

—

Good NG

— — — —

— — — —

Good NG

Good NG

Checking condition Equivalent to rating Equivalent to rating 1,600 rpm Equivalent to rating 1,700 rpm Equivalent to rating 1,800 rpm Equivalent to rating 1,900 rpm Equivalent to rating 2,000 rpm

cc/min

Standard value (Reference value) Max. 10

cc/min

960

cc/min

1,020

cc/min

1,080

cc/min

1,140

cc/min

1,200

Unit

Measured value

Good NG

Speed: Return rate:

95E-5 Series

40 Troubleshooting

SEN02186-00

*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 : 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

SEN02186-00

40 Troubleshooting

E-36 Code [689/CA689] Eng. Ne Speed Sensor Error Error code

Failure code

689

CA689


Trouble

1

Eng. Ne Speed Sensor Error

• Abnormality occurred in engine Ne speed sensor circuit. • Operates with signals of Bkup speed sensor. • Running engine stops (when Bkup speed sensor is also abnormal). • Stopped engine cannot be started (when Bkup speed sensor is also abnormal). • Different machine models may have different connector Nos.

Causes 1


Defective sensor power supply If code [238/CA238] is indicated, carry out troubleshooting for it system first. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.


Wiring harness between ENG1 (female) (26) – NE (female) (1)

Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG1 (female) Ground fault in wiring harness (26) – NE (female) (1) and chassis ground 3 (Short circuit with GND circuit) Wiring harness between ENG1 (female) (44) – NE (female) (2) and chassis ground

Resistance

Min. 1 Mz

Resistance

Min. 1 Mz

Wiring harness between ENG1 (female) (42) – NE (female) (3) and chassis ground

Resistance

Min. 1 Mz



4

12


Wiring harness between ENG1 (female) (26) – NE (female) (1) and wiring harness between ENG1 (female) (44) – NE (female) (2)

Resistance

Min. 1 Mz


Resistance

Min. 1 Mz


Resistance

Min. 1 Mz

5

Check Ne speed sensor directly for defective mount (defective Defective mount of sensor or clearance) or check rotation sensing part (crankshaft pulley) defective rotation sensing part directly for defect.

6

Defective engine Ne speed sensor

If causes 1 – 5 are not detected, engine Ne speed sensor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)

95E-5 Series

40 Troubleshooting


SEN02186-00

Causes 7 Defective engine controller

Standard value in normal state/Remarks on troubleshooting If causes 1 – 6 are not detected, engine controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)

Reference: Bkup speed sensor = Cam speed sensor Circuit diagram related to engine Ne speed sensor

95E-5 Series

13

SEN02186-00

40 Troubleshooting

E-37 Code [731/CA731] Eng. Bkup Speed Sensor Phase Error Error code

Failure code

731

CA731


Trouble

1

Eng. Bkup Speed Sensor Phase Error

• Engine Bkup speed sensor circuit detected abnormality in phase. • Controls with signals of engine Ne speed sensor. • Running engine stops (when Ne speed sensor is also abnormal). • Stopped engine cannot be started (when Ne speed sensor is also abnormal).

Related information


Cause


1

Defective engine Ne speed sensor system

Engine Ne speed sensor may be defective. Carry out troubleshooting for [689/CA698] (E-36).

2

Defective engine Bkup speed sensor system

Engine Bkup speed sensor may be defective. Carry out troubleshooting for [778/CA778] (E-39).


14

95E-5 Series

40 Troubleshooting

SEN02186-00

E-38 Code [757/CA757] All Persistent Data Lost Error Error code

Failure code

757

CA757


Trouble

1

All Persistent Data Lost Error

• All data in engine controller are lost. • None in particular. • Engine continues operation normally, but it may stop during operation or may not be able to start.


95E-5 Series

Cause


15

SEN02186-00

40 Troubleshooting

E-39 Code [778/CA778] Eng. Bkup Speed Sensor Error Error code

Failure code

778

CA778


Trouble

1

Eng. Bkup Speed Sensor Error

• Abnormality occurred in engine Bkup speed sensor circuit. • Operates with signals of Ne speed sensor. • Running engine stops (when Ne speed sensor is also abnormal). • Stopped engine cannot be started (when Ne speed sensor is also abnormal). • Different machine models may have different connector Nos.

Causes 1


Defective sensor power supply If code [187/CA187] or [227/CA227] is indicated, carry out trousystem bleshooting for it first. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.


Wiring harness between ENG1 (female) (36) – CAM (female) (1)

Resistance

Max. 1 z


Resistance

Max. 1 z


Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG1 (female) (36) – CAM (female) (1) and chassis ground


3

Resistance

Min. 1 Mz

Ground fault in wiring harness (Short circuit with GND circuit) Wiring harness between ENG1 (female) (48) – CAM (female) (2) and chassis ground

Resistance

Min. 1 Mz

Wiring harness between ENG1 (female) (37) – CAM (female) (3) and chassis ground

Resistance

Min. 1 Mz


4

5

16


Wiring harness between ENG1 (female) (36) – CAM (female) (1) and between ENG1 (female) (48) – CAM (female) (2)

Resistance

Min. 1 Mz


Resistance

Min. 1 Mz


Resistance

Min. 1 Mz

Check Bkup speed sensor directly for defective mount (defective Defective mount of sensor or clearance) or check rotation sensing part (in supply pump) defective rotation sensing part directly for defect.

95E-5 Series

40 Troubleshooting

SEN02186-00

Causes Possible causes and standard value in normal state

6

Defective engine Bkup speed sensor


Standard value in normal state/Remarks on troubleshooting If causes 1 – 5 are not detected, engine Bkup speed sensor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.) If causes 1 – 6 are not detected, engine controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)

Reference: Bkup speed sensor = Cam speed sensor Circuit diagram related to engine Bkup speed sensor

95E-5 Series

17

SEN02186-00

40 Troubleshooting

E-40 Code [1633/CA1633] KOMNET Dtalink Timeout Error Error code

Failure code

1633

CA1633

Trouble

1

KOMNET Dtalink Timeout Error

Contents of trouble

• Abnormality occurred in circuit of KOMNET communication with machine.

Action of controller

• Operates in default mode or maintains condition when abnormality occurs.



18

Cause


Carry out troubleshooting on 1 machine side

This fault is detected and indicated when KOMNET communication with machine monitor or controller on the machine side is abnormal. Accordingly, contents of troubleshooting depends on machine model. See Shop manual for machine.

95E-5 Series

40 Troubleshooting

SEN02186-00

E-41 Code [2185/CA2185] Throttle Sens. Sup. Volt. High Error

1


Failure code

2185

CA2185


Trouble


• Signal voltage in throttle sensor power supply (5 V) circuit is abnormally high. • Sets throttle angle with signal other than throttle sensor signal and continues operation (depending on each model) • Different problems occur on different machine models.

Related information


95E-5 Series

19

SEN02186-00

40 Troubleshooting

Throttle sensor of fuel control dial type Error code

Failure code

2185

CA2185


Trouble


• Signal voltage in throttle sensor power supply (5 V) circuit is abnormally high. • Sets throttle angle with signal other than throttle sensor signal and continues operation (depending on each model). • Depends on machine model. • Different machine models may have different connector Nos.

Cause

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.

1

Defective fuel control dial (Internal trouble)

Disconnect devices at right in order. If error code disappears when a device is disconnected, that device has a defect in it.

Fuel control dial

P20 connector



Disconnection in wiring harness (Disconnection in wiring Wiring harness between CE2 (female) (27) 2 or defective contact in connec- – P20 (female) (1) tor) Wiring harness between CE2 (female) (28) – P20 (female) (3)

Max. 1 z

Resistance

Max. 1 z


4

Ground fault in wiring harness Wiring harness between CE2 (female) (27) (Short circuit with GND circuit) – P20 (female) (1) and chassis ground

Resistance

Min. 1 Mz

Wiring harness between CE2 (female) (28) – P20 (female) (3) and chassis ground

Resistance

Min. 1 Mz

Short circuit in wiring harness (with another wiring harness)


20

Resistance

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between CE2 (female) (27) – P20 (female) (1) and between CE2 (female) (28) – P20 (female) (3)

Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. CE2

Voltage

Between (27) – (28)

4.75 – 5.25 V

95E-5 Series

40 Troubleshooting

SEN02186-00

Circuit diagram related to throttle sensor of fuel control dial type (Case of PC128/138US-8)

95E-5 Series

21

SEN02186-00

40 Troubleshooting

E-42 Code [2186/CA2186] Throttle Sens. Sup. Volt. Low Error Error code

Failure code

2186

CA2186


Trouble

1

Throttle Sens. Sup. Volt. Low Error

• Signal voltage in throttle sensor power supply (5 V) circuit is abnormally low. • Sets throttle angle with signal other than throttle sensor signal and continues operation (depending on each model). • Depends on machine model.


22

Cause


95E-5 Series

40 Troubleshooting

SEN02186-00

E-43 Code [2249/CA2249] Rail Press. Very Low Error Error code

Failure code

2249

CA2249


Trouble

1

Rail Press. Very Low Error

• Supply pump does not feed fuel (level 2). • Limits common rail pressure. • Output drops.


95E-5 Series

Cause


23

SEN02186-00

40 Troubleshooting

E-44 Code [2311/CA2311] Abnormality in IMV solenoid Error code

Failure code

2311

CA2311


Trouble

1

Abnormality in IMV solenoid

• Resistance in supply pump actuator is abnormally high or low. • None in particular. • Engine output drops.

Related information Causes 1

Defective related system

Standard value in normal state/Remarks on troubleshooting If another failure code is indicated, carry out troubleshooting for it. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

2


Defective supply pump actuator

PREG (Male)

Resistance

Between (1) – (2)

Max. 1 z


Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring harwithout turning starting switch ON. ness Wiring harness between ENG1 (female) (10) Resis3 (Disconnection in wiring or Max. 1 z – PREG (female) (2) tance defective contact in connecWiring harness between ENG1 (female) (14) Resistor) Max. 1 z – PREG (female) (1) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harness 4 (Short circuit with GND circuit) Wiring harness between ENG1 (female) (14) ResisMin. – PREG (female) (1) tance 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 5 Defective engine controller

24

ENG1 (Female)

Resistance

Between (4) – (10)

Max. 1 z


Min. 1 Mz

95E-5 Series

40 Troubleshooting

SEN02186-00

Circuit diagram related to supply pump actuator (metering unit)

95E-5 Series

25

SEN02186-00

40 Troubleshooting

E-45 Code [2555/CA2555] Grid Heater Relay Volt. Low Error Error code

Failure code

2555

CA2555


Trouble

1

Grid Heater Relay Volt. Low Error

• There is disconnection in intake air heater relay. • None in particular. • Engine does not start easily at low temperature.


26

Cause


95E-5 Series

SEN02186-00

40 Troubleshooting

E-46 Code [2556/CA2556] Grid Heater Relay Volt. High Error Error code

Failure code

2556

CA2556


Trouble

1

Grid Heater Relay Volt. High Error

• There is short circuit in intake air heater relay. • None in particular. • Engine does not start easily at low temperature. • Condition for driving heater relay depends on machine. • Different machine models may have different connector Nos. Cause

1

Defective intake air heater relay (Internal trouble)

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. RHR (male)

Resistance

Between (1) – (2)

200 – 400 z


Disconnection in wiring harness (Disconnection in wiring Wiring harness between CE02 (female) 2 or defective contact in connec- (44) – RHR (female) (2) tor) Wiring harness between CE02 (female) (54) – RHR (female) (1) Possible causes and standard value in normal state

Resistance

Max. 1 z

Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between CE02 (female) Ground fault in wiring harness (44) – RHR (female) (2) and chassis 3 (Short circuit with GND circuit) ground

Resistance

Min. 1 Mz

Wiring harness between CE02 (female) (54) – RHR (female) (1) and chassis ground

Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. CE02 4 Defective engine controller Between (44) – (54)

Heater relay

Voltage

Under operating condition

Max. 1 V

Under stopping condition

20 – 30 V

Note: The names and Nos. of the connectors shown above are examples.

28

95E-5 Series

40 Troubleshooting

SEN02186-00

Circuit diagram related to intake air heater

95E-5 Series

29

SEN02186-00

40 Troubleshooting

E-47 Code [(---)/B@BAZG] Eng. Oil press. Low Speed Derate Error code

Failure code

–

B@BAZG


Trouble

1

Eng. Oil press. Low Speed Derate

• Engine oil pressure is below operating range. • Limits output and continues operation (Limits fuel injection rate and engine speed). • Output drops.


Causes 1


Carry out troubleshooting on machine side

This fault is indicated on only machine side when detected. Accordingly, contents of troubleshooting depends on machine model. See Shop manual for machine.

E-48 Code [(---)/B@BAZG] Eng. Oil press. Torque Derate Error code

Failure code

–

B@BAZG


Trouble

1

Eng. Oil press. Torque Derate

• Engine oil pressure is below operating range. • Limits output and continues operation (Limits fuel injection rate and engine speed). • Output drops.


30

Causes 1


Standard value in normal state/Remarks on troubleshooting This fault is indicated on only machine side when detected. Accordingly, contents of troubleshooting depends on machine model. See Shop manual for machine.

95E-5 Series

40 Troubleshooting

SEN02186-00

E-49 Code [(---)/B@BCNS] Eng. Overheat Error code

Failure code

–

B@BCNS


Trouble

1

Eng. Overheat

• Engine coolant temperature is above operating range. • Limits output and continues operation. • Output drops.


95E-5 Series

Causes 1


Standard value in normal state/Remarks on troubleshooting This fault is indicated on only machine side when detected. Accordingly, contents of troubleshooting depends on machine model. See Shop manual for machine.

31

SEN02186-00



32

SEN02184-00

Engine 1SHOP MANUAL

95E-5 Series

40 Troubleshooting

1

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

SEN02184-00

40 Troubleshooting

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

SEN02184-00

40 Troubleshooting

Method of using troubleshooting charts 1 The troubleshooting chart consists of the “questions”, “check items”, “causes”, and “troubleshooting” 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

40 Troubleshooting

SEN02184-00

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

SEN02184-00

40 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 gradually], and [Air cleaner clogging caution lamp is flashing].

6

95E-5 Series

40 Troubleshooting

SEN02184-00

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

SEN02184-00

40 Troubleshooting

S-1 Starting performance is poor

1

General causes why starting performance is poor Defective electrical system q Insufficient supply of fuel q Insufficient intake of air q Improper selection of fuel a The common rail fuel injection system (CRI) controls the fuel injection timing electrically. Accordingly, even if the starting operation is carried out, the engine may not start until the crankshaft revolves 2 turns at maximum. This phenomenon does not indicate a trouble, however.

Defective or deteriorated battery

Defective alternator (generator section)

Defective alternator (regulator section)

Defective intake air heater system

Defective injector

Stuck, seized supply pump plunger

Clogged fuel filter

Leaking or clogged fuel piping, entry of air

Clogged air breather hole of fuel tank cap

Worn piston ring, cylinder

Clogged air cleaner element

Defective contact of valve and valve seat

Causes

q

Confirm recent repair history Degree of use of machine Operated for long period

E

E

Q w w

Q

E w

Engine starts easily when warm

w

Q Q Q

Non-specified fuel is being used Replacement of filters has not been carried out according to Operation and Maintenance Manual

w

w Q Q w

Oil must be added more frequently When engine is preheated or when temperature is low, preheating monitor does not indicate normally (if monitor is installed)

w w w

During operation, charge level monitor indicates abnormal charge (if monitor is installed) w

Dust indicator is red (if indicator is installed)

w

Air breather hole of fuel tank cap is clogged Fuel is leaking from fuel piping

w

Q

When priming pump is operated, it makes no reaction or it is heavy

w Q w

Starting motor cranks engine slowly

Check items

While engine is cranked with starting motor,

If air bleeding plug of fuel filter is removed, fuel does not flow out

w w

If spill hose from injector is disconnected, little fuel spills

When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low

w Q Q

Engine does not pick up smoothly and combustion is irregular

w Q w Q

There is hunting from engine (rotation is irregular) w

Blow-by gas is excessive q

Inspect air cleaner directly

q q

When compression pressure is measured, it is found to be low

q

Troubleshooting

When air is bled from fuel system, air comes out

q

Inspect fuel filter directly

q

Carry out troubleshooting according to “No-pressure feed by supply pump (*1)” in E-mode When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change

q q

When starting switch is turned to HEAT, intake air heater mount does not become warm Is voltage 20 – 30 V between alternator terminal B and terminal E with engine at low idle?

q

Yes

q

No

q Replace

Replace

Replace

Replace

Replace

Clean

Correct

Clean

Replace

Clean

Remedy

Replace

When specific gravity of electrolyte and voltage of battery are measured, they are low

Replace

Questions

Starting performance

Became worse gradually

*1: Code [559/CA559] and code [2249/CA2249] in E-mode

8

95E-5 Series

40 Troubleshooting

SEN02184-00

S-2 Engine does not start

1

Degree of use of machine

Operated for long period

Condition of horn when starting switch is turned ON

Horn does not sound

Defective steering circuit wiring

Defective starting motor (motor section)

Defective safety relay

Defective starting switch

E E Q

When starting switch is turned to START, starting pinion does not move out

Q

w

w

w

Speed of rotation is low w

Makes grating noise

w w

Soon disengages again Q

Makes rattling noise and does not turn

Q Q

q

When specific gravity of electrolyte and voltage of battery are measured, they are low There is not voltage (20 – 30 V) between battery relay terminal B and terminal E

q

When terminal B and terminal C of starting switch are connected, engine starts

q

When terminal B and terminal C at safety relay outlet are connected, engine starts

q

Replace

Replace

Remedy

Replace

q Replace

When terminal at safety switch and terminal B at starting motor are connected, engine starts Replace

q

Replace

Even if terminal B and terminal C at safety relay outlet are connected, engine does not start

Carry out troubleshooting on applicable machine

q

Inspect flywheel ring gear directly

95E-5 Series

Q

w Q

Turn starting switch OFF, connect cord, and carry out troubleshooting at ON

w

w

When starting switch is turned ON, there is no operating sound from battery relay

When starting switch is turned to START, starting pinion moves out, but

Q

w

Horn volume is low

Battery terminal is loose

Check items

Defective battery relay

Confirm recent repair history

Battery electrolyte is low

Troubleshooting

Defective connection of battery terminal

Defective or deteriorated battery

Broken flywheel ring gear

Causes

Correct

Questions

a) Engine does not turn General causes why engine does not turn q Seized parts inside engine o See “S-4 Engine stops during operations” q Defective electrical system q Problem in drive devices on applicable machine side o Carry out troubleshooting for devices on applicable machine

—

9

Defective fuel injector

Defective common rail pressure limiter

Defective operation of overflow valve (Does not close)

Defective supply pump MPROP


Broken supply pump shaft

Seized, abnormally worn feed pump

Clogged fuel filter


Causes


b) Engine turns but no exhaust smoke comes out General causes why engine turns but no exhaust smoke comes out q Fuel is not being supplied q Supply of fuel is extremely small q Improper selection of fuel (particularly in winter)

Insufficient fuel in tank

40 Troubleshooting

Use of improper fuel

SEN02184-00

Confirm recent repair history E E


w Q w w

Exhaust smoke suddenly stopped coming out (when starting again) 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 Maintenance Manual

Q

Q E

E E

w

Air breather hole of fuel tank cap is clogged Rust and water are found when fuel tank is drained w

When fuel filter is removed, there is not fuel in it Check items

E

w

When fuel tank is inspected, it is found to be empty

w

Fuel is leaking from fuel piping

w


w Q

If air bleeding plug of fuel filter is removed, fuel does not While engine is cranked with flow out starting motor, If spill hose from injector is disconnected, little fuel spills

Q

Q

w Q

Q

w w w

Q

q


q

Inspect fuel filter directly Troubleshooting

w

E

q

Inspect feed pump directly Carry out troubleshooting according to “No-pressure feed by supply pump (*1)” in Emode

q q

Carry out troubleshooting according to “Abnormality in supply pump IMV (*2)” in Emode

q q

Inspect overflow valve directly

q

Engine can be started in reduced cylinder mode Replace

Replace

Replace

Replace

Replace

Replace

Correct

Clean

Add

Replace

Remedy

Replace

q

Fuel flows out when pressure limiter return piping is disconnected

Replace

Questions


*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

40 Troubleshooting

SEN02184-00

c) Exhaust smoke comes out but engine does not start (fuel is being injected) General causes why exhaust smoke comes out but engine does not start q Lack of rotating force due to defective electrical system q Insufficient supply of fuel q Insufficient intake of air q Improper selection of fuel

Defective intake air heater system

Defective coolant temperature sensor, wiring harness

Defective, deteriorated battery

Clogged injector, defective spray


Clogging of fuel filter

Leaking or clogged fuel system, entry of air


Use of improper fuel


Worn dynamic valve system (Valve, rocker lever, etc.)


Causes

Confirm recent repair history E


E

w

Suddenly failed to start

E w

Q

Q Q


w

w w

Oil must be added more frequently When engine is preheated or when temperature is low, preheating monitor does not indicate normally (if monitor is installed)

w w


Q

Air breather hole of fuel tank cap is clogged

w

Rust and water are found when fuel tank is drained w

When fuel filter is removed, there is not fuel in it Fuel is leaking from fuel piping

w


w Q w

Starting motor cranks engine slowly w

Check items

When engine is cranked, abnormal sound is generated around cylinder head If air bleeding plug of fuel filter is removed, fuel does not While engine is cranked with flow out starting motor, If spill hose from injector is disconnected, little fuel spills

Q

w


w

q


q

Inspect dynamic valve system directly

q

When compression pressure is measured, it is found to be low Troubleshooting

w

q


q


q

Carry out troubleshooting according to “No-pressure feed by supply pump (*1)” in E-mode

q

Engine can be started in reduced cylinder mode

q

When specific gravity of electrolyte and voltage of battery are measured, they are low Coolant temperature gauge does not indicate normally (if coolant temperature gauge is installed)

q q Replace

Replace

Replace

Replace

Replace

Correct

Clean

Replace

Replace

Clean

Remedy

Replace

When starting switch is turned to HEAT, intake air heater mount does not become warm

Replace

Questions


*1: Code [559/CA559] and code [2249/CA2249] in E-mode 95E-5 Series

11

SEN02184-00

40 Troubleshooting

S-3 Engine does not pick up smoothly

1

General causes why engine does not pick up smoothly Insufficient intake of air q Insufficient supply of fuel 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



Seized turbocharger, interference of turbocharger

Causes

q



E w

Engine pick-up suddenly became worse

E Q Q

Q w w w


w

w w

Oil must be added more frequently w


w


w

Rust and water are found when fuel tank is drained Fuel is leaking from fuel piping

w


w Q

Check items

When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Color of exhaust gas is

Q w w

Blue under light load w Q

Black

w w

When engine is cranked, interference sound is generated around turbocharger 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

w

Blow-by gas is excessive q


q

When compression pressure is measured, it is found to be low Troubleshooting

w

w

When engine is cranked, abnormal sound is generated around cylinder head

q q

Inspect valve clearance directly

q

When turbocharger is rotated by hand, it is found to be heavy

q


q


q


q Clean

Replace

Correct

Clean

Replace

Replace

Adjust

Clean

Remedy

Correct

When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change

Replace

Questions



12

95E-5 Series

40 Troubleshooting

SEN02184-00

S-4 Engine stops during operations General causes why engine stops during operations q Internal parts of engine seized q Insufficient supply of fuel q There is overheating q Problem in drive devices on applicable machine side o Carry out troubleshooting for devices on applicable machine

1

Defective starting switch wiring

Defective hydraulic pump

Defective engine controller power supply wiring

Broken auxiliary equipment (pump, compressor, etc.)


w

Broken supply pump shaft

Q w Q w

Broken, seized feed pump

Clogging feed pump gauze filter


Leaking, clogged fuel piping



Broken, seized gear train

Broken, seized crankshaft bearing

Broken, seized piston, connecting rod

Broken dynamic valve system (valve, rocker arm, etc.)

Causes



Condition when engine stopped

w w w w w Q

Engine overheated and stopped

Q

Engine stopped slowly

w

Q Q

Q Q

There was hunting and engine stopped

w Q

Q Q Q

Q Q


Q Q Q


w w

Fuel level monitor indicates low level

w

When fuel tank is inspected, it is found to be empty

w w


w


w w

Check items

Rust and water are found when fuel tank is drained Metal particles are found when oil pan is drained

w w

Does not turn at all

w w

When engine is cranked by hand

Q

Q Q

w

Turns in opposite direction

w

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 q


q

Inspect piston, connecting rod directly

q

Inspect crankshaft bearing directly

q

Troubleshooting

Inspect gear train directly

q


q

Inspect feed pump gauge filter directly

q

Inspect feed pump directly 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, etc.) is removed

q

q

Check controller power supply wiring

q Correct

—

Replace

Replace

Replace

Replace

Clean

Replace

Correct

Clean

Add

Replace

Replace

Replace

Remedy

Replace

Check starting switch wiring

Correct

Questions

Abnormal noise was heard and engine stopped suddenly




95E-5 Series

13

SEN02184-00

40 Troubleshooting

S-5 Engine does not rotate smoothly

1

General causes why engine does not rotate smoothly Air in fuel system q Defective speed sensor (Error at degree that it is not indicated)

Defective Bkup speed sensor, wiring harness

Defective Ne speed sensor, wiring harness





Clogged injector, defective spray (dirt in injector)

Causes

q



Q Q

Occurs at a certain speed range

Q Q Q Q Q

Occurs at low idle Q

Occurs even when speed is raised

Q Q

w

Occurs on slopes

w

Replacement of filters has not been carried out according to Operation and Maintenance Manual w

When fuel tank is inspected, it is found to be empty Check items


w


w Q

Troubleshooting

w



q

Q

Rust and water are found when fuel tank is drained

q


q


q

Carry out troubleshooting according to “Abnormality in Ne speed sensor (*1)” in E-mode

q Replace

Replace

Replace

Add

Remedy

Clean

Carry out troubleshooting according to “Abnormality in Bkup speed sensor (*2)” in E-mode

Replace

Hunting

Replace

Questions


*1: Code [689/CA689] in E-mode *2: Code [778/CA778] in E-mode

14

95E-5 Series

40 Troubleshooting

SEN02184-00

S-6 Engine lacks output (or lacks power) General causes why engine lacks output q Insufficient intake of air q Insufficient supply of fuel q Defective condition of fuel injection q Improper selection of fuel q There is overheating o See “S-14 Coolant temperature becomes too high (Overheating)“ q Controller is controlling in derate mode (limiting injection rate (output) because of an error in electrical system)

1

Clogged fuel spill piping

Defective boost pressure sensor, wiring harness

Defective installation of boost pressure sensor (air leakage)

Defective drive of injector (signal, solenoid)

Clogged injector, defective spray (dirt in injector)



Leaking, clogged fuel piping






Air leakage from air intake piping


Causes


E

E

Q

Q

Q

Q w Q

Gradually

Q


w Q

Q

w w


w


w

Fuel is leaking from fuel piping w

Output becomes insufficient after short stop of operation

w

Black

w w

Blue under light load

When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Check items

Q Q

w

Oil must be added more frequently

w w w

When engine is cranked, interference sound is generated around turbocharger

w


Q

High idle speed is too high Q

High idle speed under no load is normal, but speed suddenly drops when load is applied w w

Engine does not pick up smoothly and combustion is irregular There is hunting from engine (rotation is irregular)

w

Blow-by gas is excessive

w Q Q

Q Q

w

Q Q Q

Q Q

w

q


q

Inspect air intake piping directly

q q q

When boost pressure is measured, it is found to be low

q


q q

Inspect valve clearance directly Troubleshooting

Q Q

Q Q Q


Color of exhaust gas is

Q

q

Inspect fuel piping

q


q

Inspect spill port check valve directly Carry out troubleshooting according to “No-pressure feed by supply pump (*1)” in Emode

q


q q q

Inspect charge pressure sensor mount directly Carry out troubleshooting according to “Abnormality in charge pressure sensor (*2)” in E-mode

Correct

Replace

Replace

Replace

Replace

Correct

Clean

Replace

Adjust

Correct

Correct

Replace

Clean

Remedy

q Replace

Power was lost

E

Operated for long period Suddenly

Replace

Questions


*1: Code [559/CA559] and code [2249/CA2249] in E-mode *2: Code [122/CA122] and code [123/CA123] in E-mode

95E-5 Series

15

SEN02184-00

40 Troubleshooting

S-7 Exhaust smoke is black (incomplete combustion) General causes why exhaust smoke is black q Insufficient intake of air q Defective condition of fuel injection q Improper selection of fuel q There is overheating o See “S-14 Coolant temperature becomes too high (Overheating)“ q Controller is controlling in derate mode (limiting injection rate (output) because of an error in electrical system)

1 Defective coolant temperature sensor, wiring harness

Improper fuel injection pressure

Improper injection timing

Abnormally worn injector

Clogged, seized injector



Crushed, clogged muffler

Leakage of air between turbocharger and cylinder head





Causes



Questions

Color of exhaust gas is

E

E

w

Suddenly became black

w

w

Gradually became black

Q

Q w


Q Q

Non-specified fuel is being used w

Oil must be added more frequently Power was lost

E Q Q Q

w

Suddenly Gradually

Q


w

Q Q

Q

Q Q Q

w

Muffler is crushed w

Air leaks between turbocharger and cylinder head, clamp is loosened

Q Q Q

Engine is operated in low-temperature mode at normal temperature

Check items


Q w w


w


Q

Torque converter stall speed or pump relief speed is high (Fuel is injected excessively) Exhaust noise is abnormal

Q

w

Engine does not pick up smoothly and combustion is irregular

Q

Q Q Q

Q Q w w


w

If spill hose from injector is disconnected, abnormally much fuel spills q


q

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

q

Troubleshooting


q q


q

When muffler is removed, exhaust sound improves

q


q q

When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change Carry out troubleshooting according to “Abnormality in coolant temperature sensor (*2)” in Emode

q

Replace

Replace

Replace

Replace

Replace

Correct

Replace

Adjust

Correct

Clean

Replace

Remedy

Replace

q q

Confirm with INSITE or with monitoring function on applicable machine side

Replace



16

95E-5 Series

40 Troubleshooting

SEN02184-00

S-8 Oil consumption is excessive (or exhaust smoke is blue) General causes why oil consumption is excessive q Abnormal consumption of oil q Long-time operation of engine at low idle or high idle (Do not run engine at idle for more than 20 minutes continuously) q External leakage of oil q Wear of pats in lubrication system

1 Oil leakage from oil pan, cylinder head, etc.

Oil leakage from oil drain plug

Oil leakage from oil piping

Oil leakage from oil filter

Oil leakage from oil cooler

Broken oil cooler

Worn, damaged rear oil seal


Broken piston ring

Clogged breather, breather hose

Turbocharger Worn seal at blower end

Worn seal at turbine end

Worn, damaged valve (stem, guide, seal)

Dust sucked in from intake system

Causes

E E E


E w

Oil consumption suddenly increased

Q

Oil must be added more frequently

w

Oil becomes contaminated quickly

Q Q w

Q w w w w w

Outside of engine is dirty with oil w

There are loose piping clamps in intake system

w

Inside of turbocharger intake outlet pipe is dirty with oil Q w

w

There is oil in coolant w

Oil level in clutch chamber or damper chamber is high w w

Exhaust smoke is blue under light load

w w w

None q

When intake manifold is removed, dust is found inside

q

When intake manifold is removed, inside is found to be dirty abnormally Troubleshooting

Q

q q

Excessive play of turbocharger shaft

q

Check breather and breather hose directly

q q


q

Inspect rear oil seal directly

q q

Pressure-tightness test of oil cooler shows there is leakage

q q q q

95E-5 Series

Replace

Replace

Correct

Replace

Replace

Clean

Replace

Replace

Correct

Remedy

Correct

There is external leakage of oil from engine

Correct

Amount of blow-by gas

Q

Excessive

Correct

Check items

Inside of turbocharger exhaust outlet pipe is dirty with oil

Correct


Correct

Questions


17

SEN02184-00

40 Troubleshooting

S-9 Oil becomes contaminated quickly

1


Q

Exhaust smoke is bad

Q

w

Oil must be added more frequently Metal particles are found when oil filter is drained

Q Q

Inside of exhaust pipe is dirty with oil

w

w w

Color of exhaust gas is Amount of blow-by gas

w


w

Black Q Q w

Excessive

Q w

None q

Excessive play of turbocharger shaft

q q


q

Check breather and breather hose directly

q

Inspect oil cooler directly

q

Inspect oil filter directly

q

Spring of oil filter safety valve is hitched or broken

q Replace

Replace

Replace

Clean

Replace

Replace

Remedy

Replace

Inspect turbocharger lubrication drain tube directly

18

Clogged turbocharger lubrication drain tube

Defective oil filter safety valve

E E E



See S-7

Check items

Clogged oil filter


Engine oil temperature rises quickly

Troubleshooting

Clogged oil cooler

Clogged breather, breather hose


Worn valve, valve guide

Defective seal at turbocharger turbine end

Causes

Clean

Questions

General causes why oil becomes contaminated quickly q Entry of exhaust gas into oil due to internal wear q Clogging of lubrication passage q Use of improper fuel q Use of improper oil q Operation under excessive load

—

95E-5 Series

40 Troubleshooting

SEN02184-00

S-10 Fuel consumption is excessive

1

General causes why fuel consumption is excessive Leakage of fuel q Defective condition of fuel injection (fuel pressure, injection timing) q Excessive injection of fuel

Improper injection timing

Defective operation of injector

Defective spray by injector

Defective common rail pressure

Defective supply pump plunger

Defective feed pump oil seal

Fuel leakage from fuel filter, piping, etc.

Fuel leakage inside head cover

Defective coolant temperature sensor, wiring harness

Causes

q

E E


Condition of fuel consumption

E Q

More than for other machines of same model Q

Gradually increased Q Q

Suddenly increased

w

There is external leakage of fuel from engine

w

Combustion is irregular w

w


w Q

Low idle speed is high

Q

Torque converter stall speed or pump relief speed is high Color of exhaust gas is

Q Q

Black

Q Q

Q

White

q

Remove head cover and inspect directly

q

Inspect feed pump oil seal directly

q


q


q

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 Replace

Replace

Replace

Correct

Correct

Remedy

q Replace

q


Correct

Check items

Engine oil level rises and oil smells of diesel fuel

Troubleshooting

Q Q Q Q

Replace


Replace

Questions



95E-5 Series

19

SEN02184-00

40 Troubleshooting

S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)1 General causes why oil is in coolant q Internal leakage in lubrication system q Internal leakage in cooling system

Broken hydraulic oil cooler or power train oil cooler on applicable machine side

Broken oil cooler core, O-ring

Holes caused by pitting

Cracks inside cylinder block

Broken cylinder head, head gasket

Causes

Degree of use of machine Oil level

E E

Operated for long period Q

Suddenly rose

Q Q Q Q Q w

w

There are excessive air bubbles in radiator, coolant spurts back 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

q q

Carry out troubleshooting on applicable machine q Replace

Inspect cylinder block, liner directly

Replace

q

Pressure-tightness test of cylinder head shows there is leakage Pressure-tightness test of oil cooler shows there is leakage Remedy

Replace

Troubleshooting

Check items

Oil level has risen and oil is milky

20

Q

Q Q

Gradually rose

Hard water is being used as coolant

Replace

Questions


—

95E-5 Series

40 Troubleshooting

SEN02184-00

S-12 Oil pressure drops

1

General causes why oil pressure drops q Leakage, clogging, wear or lubrication system q Defective oil pressure control q Improper selection of fuel (improper viscosity) q Deterioration of oil due to overheating

Defective oil level sensor, wiring harness

Leaking, crushed, clogged hydraulic piping

Clogged oil filter

Defective regulator valve

Defective oil pump

Clogged, broken pipe in oil pan

Clogged strainer in oil pan

Coolant, fuel in oil

Lack of oil in oil pan

Worn journal of bearing

Causes


E


E

Q w

Oil pressure monitor indicates low oil pressure (if monitor is installed) Q

Non-specified oil is being used

Q


Oil pressure monitor (if installed)

w w

Indicates pressure drop at low idle Indicates pressure drop at low, high idle

Q

Indicates pressure drop on slopes

w

w w w Q w

Oil level monitor indicates oil level drop (if monitor is installed)

w

Oil level in oil pan is low

w

Q w w

External hydraulic piping is leaking, crushed w

Oil is milky or smells of diesel oil Metal particles are found when oil pan is drained

w

Metal particles are found when oil filter is drained

w

Metal particles are found in oil filter

q

Q

Inspect oil pan strainer, pipe directly

See S-13

Check items

Sometimes indicates pressure drop

Troubleshooting

E

Oil pump rotation is heavy, there is play in oil pump Valve and spring of regulator valve are fatigued, damaged Inspect oil filter directly

q q q q q q

95E-5 Series

Correct

Replace

Adjust

Replace

Clean

—

Clean

Add

Remedy

Replace

If oil level sensor is replaced, oil level monitor indicates normally

Replace

Questions


21

SEN02184-00

40 Troubleshooting

S-13 Oil level rises (Entry of coolant or fuel)

1

General causes why oil level rises q Coolant in oil (milky) q Fuel in oil (smells diluted diesel fuel) a If oil is in coolant, carry out troubleshooting for “S-11 Oil is in coolant”


Check items

E E

E

w

Fuel must be added more frequently

w

Coolant must be added more frequently

Q

There is oil in coolant

Q Q Q Q

Q w

w

Oil is milky

Q

When engine is started, drops of water come from muffler

Q

w Q

When radiator cap is removed and engine is run at low idle, an abnormal number of bubbles appears, w or coolant spurts back

Q Q

Exhaust smoke is white

w

Oil level in clutch chamber or damper chamber is low

w

Oil level in hydraulic tank of machine is low q


q

Remove injector and inspect O-ring.

q q

Inspect cylinder block, liner directly

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 Replace

Replace

Correct

Replace

Replace

Replace

Remedy

Replace

Inspect seal of auxiliary equipment directly

22

Defective seal of auxiliary equipment (pump, compressor)

Defects in supply pump

Broken oil cooler core, O-ring

Worn, damaged rear oil seal


Cracks inside cylinder block

E


Oil smells of diesel fuel

Troubleshooting

Broken injector, O-ring


Replace

Questions


Causes

95E-5 Series

40 Troubleshooting

SEN02184-00

S-14 Coolant temperature becomes too high (overheating) General causes why coolant temperature becomes too high q Lack of cooling air (deformation, damage of fan) q Drop in heat dissipation efficiency q Problem in coolant circulation system q Rise in oil temperature in power train o Carry out troubleshooting on applicable machine

1 Rise in power train oil temperature on applicable machine side

Defective coolant temperature gauge

Slipping fan belt, worn fan pulley

Defective radiator cap (pressure valve)

Clogged radiator core

Clogged, crushed radiator fins

Defective operation of thermostat

Broken water pump

Lack of coolant

Clogged, broken oil cooler



Causes

Questions

Confirm recent repair history Degree of use of machine Condition overheating Coolant temperature gauge (if installed)

E E


E E Q w

Sudden overheated

Q Q w w

Always tends to overheat Q

Rises quickly

Q

w w

Does not go down from red range w

Radiator coolant level monitor indicates drop of coolant level (if monitor is installed) w Q

Engine oil level has risen, oil is milky

w

Fan belt tension is low w

When fan pulley is turned, it has play w

Milky oil is floating on coolant w

Check items

There are excessive air bubbles in radiator, coolant spurts back When light bulb is held behind radiator core, no light passes through

w

Radiator shroud, inside of underguard on applicable machine side are clogged with dirt or mud

w

w

w

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 Power train oil temperature enters red range faster than engine coolant temperature (if oil temperature gauge and coolant temperature gauge are installed)

w

q


q

Inspect oil cooler directly

q

Temperature difference between upper and lower tanks of radiator is large When operation of thermostat is carried out, it does not open at cracking temperature

q 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

95E-5 Series

Correct

Replace

Correct

Correct

Replace

Replace

Add

Replace

Replace

Remedy

Replace

When coolant temperature is measured, it is found to be normal

Replace

Troubleshooting


q

Inspect cylinder liner directly

—

23

SEN02184-00

40 Troubleshooting

S-15 Abnormal noise is made

1

General causes why abnormal noise is made q Abnormality due to defective parts q Abnormal combustion q Air sucked in from intake system a Judge if the noise is an internal noise or an external noise before starting troubleshooting. a The engine is operated in the low-temperature mode while it is not warmed up sufficiently. Accordingly, the engine sound becomes a little larger. This does not indicate abnormality, however. a When the engine is accelerated, it is operated in the acceleration mode and its sound becomes a little larger for up to about 3 seconds. This does not indicate abnormality, however.

Improper fuel injection timing (abnormality in coolant temperature sensor, boost temperature sensor)

Dirt caught in injector

Clogged, seized injector

Deformed cooling fan, loose fan belt, interference of fan belt

Removed, seized bushing

Improper gear train backlash

Excessive wear of piston ring, cylinder


Defective inside of muffler (dividing board out of position)

Broken dynamic valve system (valve, rocker lever)

Interference of turbocharger, seized turbocharger

Leakage of air between turbocharger and cylinder head

Causes

Degree of use of machine Condition of abnormal noise

E


Q

Gradually occurred

Q Q

Non-specified fuel is being used Oil must be added more frequently

w


w

w

w

Air leaks between turbocharger and cylinder head

w


w


w w

When engine is cranked, beat noise is generated around muffler Check items

Q

Q Q

Suddenly occurred

When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Color of exhaust gas is

w Q w

Blue under light load Q w

Black

Q w

Engine does not pick up smoothly and combustion is irregular Q

Abnormal noise is loud when engine is accelerated

Q Q

q

When turbocharger is rotated by hand, it is found to be heavy

q


q

When muffler is removed, abnormal noise disappears Troubleshooting

Q w


q


q


q q


q

Inspect fan and fan belt directly When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change

q q q

Abnormal noise is heard only when engine is started

q

24

Replace

Replace

Correct

Replace

Replace

Replace

Adjust

Replace

Replace

Replace

Remedy

Replace


Replace

Questions


95E-5 Series

40 Troubleshooting

SEN02184-00

S-16 Vibration is excessive

1

General causes why vibration is excessive q Defective parts (abnormal wear, breakage) q Misalignment between engine and chassis q Abnormal combustion a If abnormal noise is made and vibration is excessive, carry out troubleshooting for “S-15 Abnormal noise is made”, too.

Broken output shaft, parts in damper on applicable machine side

Misalignment between engine and devices on applicable machine side

Loose engine mounting bolts, broken cushions

Improper fuel injection timing (abnormality in coolant temperature sensor, boost temperature sensor)

Worn camshaft bushing

Improper gear train backlash

Worn main bearing, connecting rod bearing

Stuck dynamic valve system (valve, rocker lever)

Causes

Degree of use of machine Condition of vibration

E


E Q

Q

Q

Non-specified oil is being used

Q

Q


w

w

Gradually increased

Metal particles are found when oil pan is drained

w

w

Oil pressure is low at low idle

Q

Q

Q

Q

Vibration occurs at mid-range speed Q

Vibration follows engine speed Exhaust smoke is black

w


q

Q

Q Q Q Q

q

Inspect main bearing and connecting rod bearing directly Troubleshooting

E

Q

Suddenly increased

q


q

Inspect camshaft bushing directly

q


q

Inspect engine mounting bolts and cushions directly

q

When alignment is checked, radial runout or facial runout is detected

q

95E-5 Series

Adjust

Replace

Replace

Replace

Replace

Replace

Remedy

Replace

Inspect output shaft or inside of damper directly

Replace

Check items

Questions


25

SEN02184-00

40 Troubleshooting

KOMATSU 95E-5 Series Diesel engine Form No. SEN02184-00


26

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