Komatsu SAA4D95LE-5-A DIESEL ENGINE CX50 Forklift Truck Shop Manual SM204 4D95LE-BE3 – PDF DOWNLOAD

Description

Komatsu SAA4D95LE-5-A DIESEL ENGINE CX50 Forklift Truck Shop Manual SM204 4D95LE-BE3 – PDF DOWNLOAD

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DESCRIPTION:

Komatsu SAA4D95LE-5-A DIESEL ENGINE CX50 Forklift Truck Shop Manual SM204 4D95LE-BE3 – PDF DOWNLOAD

CX50 Forklift Truck, EPA Tier 3 Compliant
Diesel Models FD40ZTU/F40TU/45TU/50ATU-10
S/N 133001~

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.

TABLE OF CONTENTS:

Komatsu SAA4D95LE-5-A DIESEL ENGINE CX50 Forklift Truck Shop Manual SM204 4D95LE-BE3 – PDF DOWNLOAD

SM204_01_FOREWORD[1] 1
Safety notice 2
How to read the shop manual 6
Explanation of terms for maintenance standard 8
Handling of electric equipment and hydraulic component 10
Handling of connectors newly used for engines 19
How to read electric wire code 22
Precautions when carrying out operation 25
Method of disassembling and connecting push-pull type coupler 28
Standard tightening torque table 31
Conversion table 35
SM204_02_SPECIFICATION[1] 40
Outline 40
Specifications 42
General view 44
Dimensions table 48
Weight table 49
Engine performance curves 50
SM204_03_STANDARDS[1] 53
General structure 53
Air intake and exhaust unit 55
Turbocharger 57
Cylinder head 60
Cylinder block 62
Cylinder 65
Crankshaft 68
Camshaft 69
Piston, piston ring and piston pin 70
Connecting rod 71
Flywheel and flywheel housing 72
Timing gear 74
Valve system 77
Valve, valve guide 79
Rocker arm shaft, push rod and tappet 80
Lubrication system diagram 81
Oil pump 82
Regulator valve 84
Oil filter 85
Fuel system diagram 87
Supply pump 88
Fuel injection injector 90
Fuel filter 91
Common rail 92
Various sensor, actuator 93
Various connector 95
Cooling system diagram 97
Water pump 98
Cooling fan drive and thermostat 100
Starting and charging system electrical circuit diagram 104
Alternator 105
Starting motor 109
Electric heater 111
Engine controller 113
SM204_04_STD_VALUES[1] 114
SM204_05_TEST_AND_ADJ[1] 118
Testing and adjusting tools list 118
Testing exhaust temperature 119
Adjusting valve clearance 120
Testing compression pressure 122
Testing blow-by pressure 124
Testing oil pressure 125
Handling fuel system parts 126
Releasing residual pressure in fuel system 126
Testing fuel pressure 127
Reduced cylinder mode operation 128
No-injection cranking 128
Testing leakage from pressure limiter and return rate from injector 129
Bleeding air from fuel circuit 132
Testing fuel system for leakage 134
Testing and adjusting alternator belt tension 135
Handling controller voltage circuit 136
Functions of troubleshooting tool and check of failure code 137
SM204_06_TROUBLE[1] 141
General information on troubleshooting 141
Failure code table 143
Information in troubleshooting table (E-mode) 145
Method of using troubleshooting charts (S-mode) 147
Troubleshooting for mechanical system (S-mode) 151
Troubleshooting for electrical system (E-mode) 169
SM204_07_DISASSY_AND_ASSY[1] 250
How to read this manual 250
Coating materials list 251
Special tools list 254
General disassembly of engine 255
Disassembly and assembly procedure for fuel supply pump unit 284
Disassembly and assembly procedure for oil seal units 286
SM204-SAA4D95LE5A(TIER3-UL)MAR2009_031709[1] 288

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PLEASE NOTE:

• This is the SAME exact manual used by your dealers to fix your vehicle.
• The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
• Any queries / doubts regarding your purchase, please feel free to contact [email protected]

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