Komatsu Diesel Export FD40ZY/35Y/40Y/45Y/50AY-10 S4D95LE-3 Diesel Engine CX50 Forklift Truck Service Manual SM206 – PDF

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Komatsu Diesel Export FD40ZY/35Y/40Y/45Y/50AY-10 S4D95LE-3 Diesel Engine CX50 Forklift Truck Service Manual SM206 4D95LE-BE3 – PDF DOWNLOAD

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Komatsu Diesel Export FD40ZY/35Y/40Y/45Y/50AY-10 S4D95LE-3 Diesel Engine CX50 Forklift Truck Service Manual SM206 4D95LE-BE3 – PDF DOWNLOAD

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Komatsu Diesel Export FD40ZY-10 FD35Y-10 FD40Y-10 FD45Y-10 FD50AY-10 S4D95LE-3 Diesel Engine CX50 Forklift Truck Service Manual SM206 4D95LE-BE3 – PDF DOWNLOAD

FOREWORD:
GENERAL:
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an
accurate understanding of the product and by showing him the correct way to perform repairs and make judgements.
Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service
workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further
divided into the each main group of components.
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
This 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.
In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance
standards.
TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as adjustments to
be made at completion of the checks and repairs.
Troubleshooting charts correlating “Problems” with “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the procedures for removing, installing, disassembling and assembling each component,
as well as precautions for them

TABLE OF CONTENTS:

Komatsu Diesel Export FD40ZY/35Y/40Y/45Y/50AY-10 S4D95LE-3 Diesel Engine CX50 Forklift Truck Service Manual SM206 4D95LE-BE3 – PDF DOWNLOAD

SM206_01_FOREWORD[1] 1
SAFETY NOTICE 2
GENERAL 4
HOW TO READ THE SHOP MANUAL 5
HOISTING INSTRUCTIONS 6
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER 7
COATING MATERIALS 9
STANDARD TIGHTENING TORQUE 11
ELECTRIC WIRE CODE 14
CONVERSION TABLE 15
UNITS 21
SM206_02_GEN_INFO[1] 22
GENERAL 22
SPECIFICATIONS 24
WEIGHT TABLE 25
OVERALL DRAWING 26
DIMENSION TABLE 28
ENGINE PERFORMANCE CURVE 29
SM206_03_STANDARDS[1] 31
GENERAL STRUCTURE 31
INTAKE AND EXHAUST SYSTEM 33
TURBOCHARGER 35
CYLINDER HEAD 38
CYLINDER BLOCK 41
CYLINDER 44
MAIN REVOLVING SYSTEM 45
CRANKSHAFT 47
PISTON, PISTON RING AND PISTON PIN 48
CONNECTING ROD 49
FLYWHEEL AND FLYWHEEL HOUSING 50
TIMING GEAR 53
VALVE SYSTEM 56
CAMSHAFT 58
ROCKER ARM SHAFT, PUSH ROD AND TAPPET 59
VALVE, VALVE GUIDE 60
LUBRICATION SYSTEM CHART 61
OIL PUMP 62
REGULATOR VALVE 64
OIL FILTER MOUNT 65
OIL FILTER 66
FUEL SYSTEM CHART 67
FUEL INJECTION PUMP 68
FUEL INJECTION NOZZLE 70
FUEL FILTER 71
COOLING SYSTEM CHART 72
WATER PUMP 73
FAN DRIVE AND THERMOSTAT 75
STARTING AND CHARGING SYSTEM ELECTRICAL CIRCUIT DIAGRAM 79
ALTERNATOR 80
STARTING MOTOR 81
ENGINE STARTING DEVICE 82
SM206_04_TEST_AND_ADJ[1] 83
ADJUSTING VALVE CLEARANCE 84
MEASURING COMPRESSION PRESSURE 86
ADJUSTING FUEL INJECTION PRESSURE 87
TESTING AND ADJUSTING FUEL INJECTION TIMING 88
FUEL INJECTION PUMP CALIBRATION DATA 93
PERFORMANCE TEST 95
SM206_05_TROUBLE[1] 98
METHOD OF USING TROUBLESHOOTING CHARTS 98
POINTS TO REMEMBER WHEN TROUBLESHOOTING 102
TROUBLESHOOTING CHARTS 103
TESTING AND ADJUSTING TOOL LIST 121
TESTING AND ADJUSTING DATA 122
SM206_06_DISASSY_AND_ASSY[1] 123
SPECIAL TOOL LIST 123
OVERALL DISASSEMBLY, ASSEMBLY 124
DISASSEMBLY 125
ASSEMBLY 137
SM206_07_PARTS_REP_AND_REPLACE[1] 153
GRINDING CYLINDER HEAD MOUNTING SURFACE 153
REPLACING VALVE GUIDE 154
GRINDING VALVE 155
REPLACING CAMSHAFT BUSHING 156
REPLACING CRANKSHAFT GEAR 158
REPLACING CAM GEAR 159
REPLACING FLYWHEEL RING GEAR 160
PROCEDURE FOR PRESSURE TEST 161
CYLINDER LINER 162
MACHINING DRAWING FOR CYLINDER BLOCK BORE 163
ADDITIONAL MACHINING OF CAM JOURNAL 164
GRINDING CRANKSHAFT 165
REPLACING CONNECTING ROD SMALL END BUSHING 166

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PLEASE NOTE:

• This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
• This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
• Require some other service manual or have any queries: please WRITE to us at [email protected]

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