Komatsu SAA4D95LE-5 Diesel Engine Shop Manual – PDF DOWNLOAD 

Description

Komatsu SAA4D95LE-5 Diesel Engine Shop Manual – PDF DOWNLOAD

FILE DETAILS:

Komatsu SAA4D95LE-5 Diesel Engine Shop Manual – PDF DOWNLOAD 

Language : English
Pages : 614
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Komatsu SAA4D95LE-5 Diesel Engine Shop Manual – PDF DOWNLOAD 

How to read the shop manual 1
1. Composition of shop manual
This shop manual contains the necessary technical information for services performed in a workshop.
For ease of understanding, the manual is divided into the following sections.
00. Index and foreword
This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard
This section explains the structure, function, and maintenance standard values of each component.
The structure and function sub-section explains the structure and function of each component. It
serves not only to give an understanding of the structure, but also serves as reference material for
troubleshooting. The maintenance standard sub-section explains the criteria and remedies for 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 Diesel Engine Shop Manual – PDF DOWNLOAD 

LIFT TRUCK MODEL SERIAL No.
FD40Z-10 133001 and up
FD35/40/45-10 133001 and up
FD50A-10 133001 and up
FH35/40/45/50-1 138001 and up
FD60/70/80-10 55001 and up

4D95LE-BE6(00)-MA4 3
00 Index and foreword 3
100 Index and foreword 3
Table of contents 5
Safety notice 10
How to read the shop manual 14
Explanation of terms for maintenance standard 16
Handling of electric equipment and hydraulic component 18
Handling of connectors newly used for engines 27
How to read electric wire code 30
Precautions when carrying out operation 33
Method of disassembling and connecting push-pull type coupler 36
Standard tightening torque table 39
Conversion table 43
4D95LE-BE4(01)-MA4 49
01 Specification 49
100 Specification 49
Outline 50
Specifications 52
General view 56
Dimensions table 62
Weight table 63
Engine performance curves 64
4D95LE-BE5(10)-MA4 69
10 Structure, function and maintenance standard 69
100 Structure, function and maintenancestandard 69
General structure 72
Air intake and exhaust system 74
Turbocharger 76
Engine unit 80
Cylinder block 82
Cylinder 85
Main moving parts 86
Crankshaft 88
Camshaft 89
Piston, piston ring and piston pin 90
Connecting rod 91
Flywheel and flywheel housing 92
Timing gear 96
Valve system 100
Valve, valve guide 102
Rocker arm shaft, push rod and tappet 103
Lubrication system 105
Oil pump 106
Regulator valve 108
Oil filter 109
Fuel system 112
Supply pump 113
Fuel injection injector 115
Fuel filter 116
Common rail 117
Various sensor, actuator 118
Various connector 120
Cooling system 123
Water pump 124
Cooling fan drive and thermostat 126
Electrical equipment 131
Alternator 132
Starting motor 136
Starting aid 139
Engine controller 141
4D95LE-BE4(20)-MA4 143
20 Standard value table 143
100 Standard value table 143
Standard service value table for testing, adjusting, and troubleshooting 144
Running-in standard and performance test standard 147
4D95LE-BE4(30)-MA4 151
30 Testing and adjusting 151
100 Testing and adjusting 151
Testing and adjusting tools list 152
Testing exhaust temperature 153
Adjusting valve clearance 154
Testing compression pressure 156
Testing blow-by pressure 158
Testing oil pressure 159
Handling fuel system parts 160
Releasing residual pressure infuel system 160
Testing fuel pressure 161
Reduced cylinder modeoperation 162
No-injection cranking 162
Testing leakage from pressurelimiter and return rate from injector 163
Bleeding air from fuel circuit 166
Testing fuel system for leakage 168
Testing and adjusting alternator belt tension 169
Handling controller voltage circuit 170
Functions of troubleshooting tool and check of failure code 171
Method of indicating failure code with troubleshooting tool 172
4D95LE-BE5(40)-MA4 177
40 Troubleshooting 177
100 Troubleshooting 177
General information on troubleshooting 182
Failure code table 184
Information in troubleshooting table (E-mode) 188
Method of using troubleshooting charts (S-mode) 192
Troubleshooting for mechanical system (S-mode) 196
S-1 Starting performance is poor 196
S-2 Engine does not start 197
S-3 Engine does not pick up smoothly 200
S-4 Engine stops during operations 201
S-5 Engine does not rotate smoothly 202
S-6 Engine lacks output (or lacks power) 203
S-7 Exhaust smoke is black (incomplete combustion) 204
S-8 Oil consumption is excessive (or exhaust smoke is blue) 205
S-9 Oil becomes contaminated quickly 206
S-10 Fuel consumption is excessive 207
S-11 Oil is in coolant (or coolant spurts back or coolant level goesdown) 208
S-12 Oil pressure drops 209
S-13 Oil level rises (Entry of coolant or fuel) 210
S-14 Coolant temperature becomes too high (overheating) 211
S-15 Abnormal noise is made 212
S-16 Vibration is excessive 213
Troubleshooting for electrical system (E-mode) 214
E-1 Failure code [111] ECM Critical Internal Failure 214
E-2 Failure code [115] Eng Ne and Bkup Speed Sensor Error 218
E-3 Failure code [122] Charge Air Press Sensor High Error 220
E-4 Failure code [123] Charge Air Press Sensor Low Error 222
E-5 Failure code [131] Throttle Sensor High Error 224
E-6 Failure code [132] Throttle Sensor Low Error 226
E-7 Failure code [143] Eng Oil press Torque Derate 227
E-8 Failure code [144] Coolant Temp Sensor High Error 228
E-9 Failure code [145] Coolant Temp Sensor Low Error 230
E-10 Failure code [146] Eng Overheat 231
E-11 Failure code [153] Charge Air Temp Sensor High Error 232
E-12 Failure code [154] Charge Air Temp Sensor Low Error 234
E-13 Failure code [187] Sensor Sup 2 Volt Low Error 235
E-14 Failure code [221] Ambient Air Press Sensor High Error 236
E-15 Failure code [222] Ambient Air Press Sensor Low Error 238
E-16 Failure code [227] Sensor Sup 2 Volt High Error 240
E-17 Failure code [234] Eng Overspeed 242
E-18 Failure code [238] Ne Speed Sensor Sup Volt Low Error 243
E-19 Failure code [239] Ne Speed Sensor Sup Volt High Error 244
E-20 Failure code [271] IMV Short Error 246
E-21 Failure code [272] IMV Open Error 248
E-22 Failure code [322] Injector #1 System Open/Short Error 250
E-23 Failure code [324] Injector #3 System Open/Short Error 252
E-24 Failure code [331] Injector #2 System Open/Short Error 254
E-25 Failure code [332] Injector #4 System Open/Short Error 256
E-26 Failure code [351] INJ Drive Circuit Error 258
E-27 Failure code [352] Sensor Sup 1 Volt Low Error 262
E-28 Failure code [386] Sensor Sup 1 Volt High Error 264
E-29 Failure code [415] Eng Oil press Low Speed Derate 266
E-30 Failure code [431] Idle validation switch error 267
E-31 Failure code [432] Idle validation action error 271
E-32 Failure code [435] Abnormality in engine oil pressure switch 272
E-33 Failure code [441] Battery voltage low error 273
E-34 Failure code [442] Battery voltage high error 273
E-35 Failure code [449] Rail Press Very High Error 274
E-36 Failure code [451] Rail Press Sensor High Error 276
E-37 Failure code [452] Rail Press Sensor Low Error 278
E-38 Failure code [553] Rail Press High Error 279
E-39 Failure code [559] Rail Press Low Error 280
E-40 Failure code [689] Eng Ne Speed Sensor Error 284
E-41 Failure code [731] Eng Bkup Speed Sensor Phase Error 286
E-42 Failure code [757] All Persistent Data Lost Error 287
E-43 Failure code [778] Eng Bkup Speed Sensor Error 288
E-44 Failure code [2185] Throttle Sens Sup Volt High Error 290
E-45 Failure code [2186] Throttle Sens Sup Volt Low Error 294
E-46 Failure code [2249] Rail Press Very Low Error 295
E-47 Failure code [2311] Abnormality in IMV solenoid 296
E-48 Failure code [2555] Grid Heater Relay Volt Low Error 298
E-49 Failure code [2556] Grid Heater Relay Volt High Error 299
Troubleshooting by failure code (Engine controller system) 303
Failure code [Troubleshooting tool: 115/KOMTRAX: CA115] Engine Neand Bkup Speed Sensors Error 304
Failure code [Troubleshooting tool: 111/KOMTRAX: CA111] EngineController Internal Error 303
Failure code [Troubleshooting tool: 122/KOMTRAX: CA122] ChargePressure Sensor High Error 306
Failure code [Troubleshooting tool: 123/KOMTRAX: CA123] ChargePressure Sensor Low Error 308
Failure code [Troubleshooting tool: 131/KOMTRAX: CA131] ThrottleSensor High Error 310
Failure code [Troubleshooting tool: 132/KOMTRAX: CA132] ThrottleSensor Low Error 312
Failure code [Troubleshooting tool: 143, 415/KOMTRAX: B@BAZG]Engine Oil Pressure Drop 313
Failure code [Troubleshooting tool: 144/KOMTRAX: CA144] CoolantTemperature Sensor High Error 314
Failure code [Troubleshooting tool: 145/KOMTRAX: CA145] CoolantTemperature Sensor Low Error 316
Failure code [Troubleshooting tool: 146/KOMTRAX: B@BCNS] EngineOverheat 317
Failure code [Troubleshooting tool: 153/KOMTRAX: CA153] ChargeTemperature Sensor High Error 318
Failure code [Troubleshooting tool: 154/KOMTRAX: CA154] ChargeTemperature Sensor Low Error 320
Failure code [Troubleshooting tool: 187/KOMTRAX: CA187] SensorPower Supply 2 Low Error 321
Failure code [Troubleshooting tool: 221/KOMTRAX: CA221] AmbientPressure Sensor High Error 322
Failure code [Troubleshooting tool: 222/KOMTRAX: CA222] AmbientPressure Sensor Low Error 324
Failure code [Troubleshooting tool: 227/KOMTRAX:CA227] SensorPower Supply 2 High Error 326
Failure code [Troubleshooting tool: 234/KOMTRAX: CA234] EngineOver-speed 328
Failure code [Troubleshooting tool: 238/KOMTRAX: CA238] Ne SpeedSensor Power Supply Low Error 329
Failure code [Troubleshooting tool: 239/KOMTRAX: CA239] Ne SpeedSensor Power Supply High Error 330
Failure code [Troubleshooting tool: 271/KOMTRAX: CA271] IMV/PCV1Short Circuit 332
Failure code [Troubleshooting tool: 272/KOMTRAX: CA272] IMV/PCV1Open Circuit 334
Failure code [Troubleshooting tool: 322/KOMTRAX: CA322] Injector #1(L#1) Open Circuit or Short Circuit 336
Failure code [Troubleshooting tool: 324/KOMTRAX: CA324] Injector #3(L#3) Open Circuit or Short Circuit 338
Failure code [Troubleshooting tool: 331/KOMTRAX: CA331] Injector #2(L#2) Open Circuit or Short Circuit 340
Failure code [Troubleshooting tool: 332/KOMTRAX: CA332] Injector #4(L#4) Open Circuit or Short Circuit 342
Failure code [Troubleshooting tool: 351/KOMTRAX: CA351] InjectorDrive Circuit Error 344
Failure code [Troubleshooting tool: 352/KOMTRAX: CA352] SensorPower Supply 1 Low Error 347
Failure code [Troubleshooting tool: 386/KOMTRAX: CA386] SensorPower Supply 1 High Error 348
Failure code [Troubleshooting tool: 428/KOMTRAX: CA428] WIF SensorHigh Error 350
Failure code [Troubleshooting tool: 429/KOMTRAX: CA429] WIF SensorLow Error 352
Failure code [Troubleshooting tool: 431/KOMTRAX: CA431] IdleValidation Switch Error 354
Failure code [Troubleshooting tool: 432/KOMTRAX: CA432] IdleValidation Process Error 358
Failure code [Troubleshooting tool: 435/KOMTRAX: CA435] Engine OilPressure Switch Error 359
Failure code [Troubleshooting tool: 441/KOMTRAX: CA441] PowerSupply Voltage Low Error 360
Failure code [Troubleshooting tool: 442/KOMTRAX: CA442] PowerSupply Voltage High Error 361
Failure code [Troubleshooting tool: 449/KOMTRAX: CA449] CommonRail Pressure High Pressure Error 2 362
Failure code [Troubleshooting tool: 451/KOMTRAX: CA451] CommonRail Pressure Sensor High Error 364
Failure code [Troubleshooting tool: 452/KOMTRAX: CA452] CommonRail Pressure Sensor Low Error 366
Failure code [Troubleshooting tool: 553/KOMTRAX: CA553] CommonRail Pressure High Pressure Error 1 367
Failure code [Troubleshooting tool: 559/KOMTRAX: CA559] SupplyPump No Pressure Feed Error 1 368
Failure code [Troubleshooting tool: 689/KOMTRAX: CA689] Engine NeSpeed Sensor Error 372
Failure code [Troubleshooting tool: 731/KOMTRAX: CA731] EngineBkup Speed Sensor Phase Error 374
Failure code [Troubleshooting tool: 757/KOMTRAX: CA757] EngineController Complete Data Loss Error 375
Failure code [Troubleshooting tool: 778/KOMTRAX: CA778] EngineBkup Speed Sensor Error 376
Failure code [Troubleshooting tool: —/KOMTRAX: CA1633] KOMNETError 378
Failure code [Troubleshooting tool: 2185/KOMTRAX: CA2185] ThrottleSensor Power Supply High Error 380
Failure code [Troubleshooting tool: 2186/KOMTRAX: CA2186] ThrottleSensor Power Supply Low Error 382
Failure code [Troubleshooting tool: 2249/KOMTRAX: CA2249] SupplyPump No Pressure Feed Error 2 383
Failure code [Troubleshooting tool: 2311/KOMTRAX: CA2311] IMVSolenoid Error 384
Failure code [Troubleshooting tool: 2555/KOMTRAX: CA2555] Intake AirHeater Relay Open Circuit 386
Failure code [Troubleshooting tool: 2556/KOMTRAX: CA2556] Intake AirHeater Relay Short Circuit 388
4D95LE-BE3(50)-MA4 391
50 Disassembly and assembly 391
100 Disassembly and assembly 391
How to read this manual 392
Coating materials list 393
Special tools list 396
General disassembly of engine 397
General assembly of engine 409
Disassembly and assembly procedure for fuel supply pump unit 426
Disassembly and assembly procedure for oil seal units 428
4D95LE-BE6-MA4 431
01 GENERAL 453
GENERAL 454
SPECIFICATIONS 456
WEIGHT TABLE 457
OVERALL DRAWING 458
ENGINE PERFORMANCE CURVE 461
11 STRUCTURE, FUNCTION ANDMAINTENANCE STANDARD 463
GENERAL STRUCTURE 464
INTAKE AND EXHAUST SYSTEM 466
TURBOCHARGER 468
ENGINE BODY 472
CYLINDER BLOCK 476
CYLINDER 479
MAIN REVOLVING SYSTEM 480
CRANKSHAFT 482
PISTON, PISTON RING AND PISTON PIN 483
CONNECTING ROD 484
FLYWHEEL AND FLYWHEEL HOUSING 486
TIMING GEAR 490
VALVE SYSTEM 494
CAMSHAFT 496
ROCKER ARM SHAFT, PUSH ROD AND TAPPET 497
VALVE, VALVE GUIDE 498
LUBRICATION SYSTEM 499
OIL PUMP 500
REGULATOR VALVE 502
OIL FILTER MOUNT 503
OIL FILTER 504
FUEL SYSTEM 505
FUEL INJECTION PUMP 506
FUEL INJECTION NOZZLE 508
FUEL FILTER 509
COOLING SYSTEM 511
WATER PUMP 512
FAN DRIVE AND THERMOSTAT 514
ELECTRICAL SYSTEM 518
ALTERNATOR 519
STARTING MOTOR 520
ENGINE STARTING DEVICE 521
12 TESTING AND ADJUSTING 523
ADJUSTING VALVE CLEARANCE 524
MEASURING COMPRESSION PRESSURE 526
ADJUSTING FUEL INJECTION PRESSURE(CRACKING PRESSURE) 527
TESTING AND ADJUSTING FUEL INJECTION TIMING 528
FUEL INJECTION PUMP CALIBRATION DATA 534
PERFORMANCE TEST 537
TROUBLESHOOTING 541
METHOD OF USING TROUBLESHOOTING CHARTS 542
POINTS TO REMEMBER WHEN TROUBLESHOOTING 546
S-1 Starting performance is poor (starting always takes time) 547
S-2 Engine does not start 548
S-3 Engine does not pick up smoothly (follow-up is poor) 551
S-4 Engine stops during operations 552
S-5 Engine does not rotate smoothly (hunting) 553
S-6 Engine lacks output (no power) 554
S-7 Exhaust smoke is black (incomplete combustion) 555
S-8 Oil consumption is excessive or exhaust smoke is blue 556
S-9 Oil becomes contaminated quickly 557
S-10 Fuel consumption is excessive 558
S-11 Oil is in coolant, or coolant spurts back, or coolant level goes down 559
S-12 Oil pressure caution lamp lights up (drop in oil pressure) 560
S-13 Oil level rises (water, fuel in oil) 561
S-14 Coolant temperature becomes too high (overheating) 562
S-15 Abnormal noise is made 563
S-16 Vibration is excessive 564
TESTING AND ADJUSTING TOOL LIST 565
TESTING AND ADJUSTING DATA 566
13 DISASSEMBLY AND ASSEMBLY 567
SPECIAL TOOL LIST 568
OVERALL DISASSEMBLY, ASSEMBLY 569
DISASSEMBLY 570
ASSEMBLY 582
15 REPAIR AND REPLACEMENT OF PARTS 599
GRINDING CYLINDER HEAD MOUNTING SURFACE 600
REPLACING VALVE GUIDE 601
GRINDING VALVE 602
REPLACING CAMSHAFT BUSHING 603
REPLACING CRANKSHAFT GEAR 605
REPLACING CAM GEAR 606
REPLACING FLYWHEEL RING GEAR 607
PROCEDURE FOR PRESSURE TEST 608
CYLINDER LINER (SPECIAL RESTORATION PART) 609
MACHINING DRAWING FOR CYLINDER BLOCK BORE 610
ADDITIONAL MACHINING OF CAM JOURNAL 611
GRINDING CRANKSHAFT 612
REPLACING CONNECTING ROD SMALL END BUSHING 613

S.V 13/12/24