Komatsu SAA4D95LE-5 S4D95LE-3 Diesel Engine Shop Manual 4D95LE-BE4 – PDF DOWNLOAD

Description

Komatsu SAA4D95LE-5 S4D95LE-3 Diesel Engine Shop Manual 4D95LE-BE4 – PDF DOWNLOAD

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DESCRIPTION:

Komatsu SAA4D95LE-5 S4D95LE-3 Diesel Engine Shop Manual 4D95LE-BE4 – PDF DOWNLOAD

SAA4D95LE-5:

LIFT TRUCK MODEL SERIAL No.
FD40Z-10                      M250-133001 and up
FD35/40/45-10            M252-133001 and up
FD50A-10                    M252-133001 and up
FH40/45/50-1              M273-138001 and up
FD60/70/80-10            M248-55001 and up

S4D95LE-3
LIFT TRUCK MODEL     SERIAL No.
FD40ZY-10                          M250-133001 and up
FD35Y-10                            M252-133001 and up
FD40Y-10                            M252-133001 and up
FD45Y-10                            M252-133001 and up
FD50AY-10                          M252-133001 and up

FD40Z-10 M250-133001 and up
FD35/40/45-10 M252-133001 and up
FD50A-10 M252-133001 and up
FH40/45/50-1 M273-138001 and up
FD60/70/80-10 M248-55001 and up

How to read the shop manual: 
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 S4D95LE-3 Diesel Engine Shop Manual 4D95LE-BE4 – PDF DOWNLOAD

4D95LE-BE4 1
00 Index and foreword 2
100 Index and foreword 2
Composition of shop manual 3
Table of contents 4
Safety notice 9
How to read the shop manual 13
Explanation of terms for maintenance standard 15
Handling of electric equipment and hydraulic component 17
Handling of connectors newly used for engines 26
How to read electric wire code 29
Precautions when carrying out operation 32
Method of disassembling and connecting push-pull type coupler 35
Standard tightening torque table 38
Conversion table 42
01 Specification 48
100 Specification 48
Outline 49
Specifications 51
General view 55
Weight table 62
Engine performance curves 63
10 Structure,function and maintenance standard 68
100 Structure,function and maintenance standard 68
General structure 71
General structure 71
Air intake and exhaust system 73
Air intake and exhaust unit 73
Turbocharger 75
Engine unit 79
Cylinder head 79
Cylinder block 81
Cylinder 84
Main moving parts 85
Crankshaft 87
Camshaft 88
Piston,piston ring and piston pin 89
Connecting rod 90
Flywheel and flywheel housing 91
Timing gear 95
Valve system 99
Valve, valve guide 101
Rocker arm shaft,push rod and tappet 102
Lubrication system 104
Lubrication system diagram 104
Oil pump 105
Regulator valve 107
Oil filter 108
Fuel system 111
Fuel system diagram 111
Supply pump 112
Fuel injection injector 114
Fuel filter 115
Common rail 116
Various sensor,actuator 117
Various connector 119
Cooling system 122
Cooling system diagram 122
Water pump 123
Cooling fan drive and thermostat 125
Electrical equipment 130
Starting and charging system electrical circuit diagram 130
Alternator 131
Starting motor 135
Starting aid 138
Engine controller 140
20 Standard value table 142
100 Standard value table 142
Standard service value table for testing, adjusting, and troubleshooting 143
Running-in standard and performance test standard 146
30 Testing and adjusting 150
100 Testing and adjusting 150
Testing and adjusting tools list 151
Testing exhaust temperature 152
Adjusting valve clearance 153
Testing compression pressure 155
Testing blow-by pressure 157
Testing oil pressure 158
Handling fuel system parts 159
Releasing residual pressure in fuel system 159
Testing fuel pressure 160
Reduced cylinder mode operation 161
No-injection cranking 161
Testing leakage from pressure limiter and return rate from injector 162
Bleeding air from fuel circuit 165
Testing fuel system for leakage 167
Testing and adjusting alternator belt tension 168
Handling controller voltage circuit 169
Functions of troubleshooting tool and check of failure code 170
40 Troubleshooting 176
100 Troubleshooting 176
General information on troubleshooting 181
Points on troubleshooting 181
Failure code table 183
Information in troubleshooting table (E-mode) 187
Method of using troubleshooting charts (S-mode) 191
Troubleshooting for mechanical system (S-mode) 195
S-1 Starting performance is poor 195
S-2 Engine does not start 196
S-3 Engine does not pick up smoothly 199
S-4 Engine stops during operations 200
S-5 Engine does not rotate smoothly 201
S-6 Engine lacks output (or lacks power) 202
S-7 Exhaust smoke is black (incomplete combustion) 203
S-8 Oil consumption is excessive (or exhaust smoke is blue) 204
S-9 Oil becomes contaminated quickly 205
S-10 Fuel consumption is excessive 206
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) 207
S-12 Oil pressure drops 208
S-13 Oil level rises (Entry of coolant or fuel) 209
S-14 Coolant temperature becomes too high (overheating) 210
S-15 Abnormal noise is made 211
S-16 Vibration is excessive 212
Troubleshooting for electrical system (E-mode) 213
E-1 Failure code [111] ECM Critical Internal Failure 213
E-2 Failure code [115] Eng Ne and Bkup Speed Sensor Error 217
E-3 Failure code [122] Charge Air Press Sensor High Error 219
E-4 Failure code [123] Charge Air Press Sensor Low Error 221
E-5 Failure code [131] Throttle Sensor High Error 223
E-6 Failure code [132] Throttle Sensor Low Error 225
E-7 Failure code [143] Eng Oil press Torque Derate 226
E-8 Failure code [144] Coolant Temp Sensor High Error 227
E-9 Failure code [145] Coolant Temp Sensor Low Error 229
E-10 Failure code [146] Eng Overheat 230
E-11 Failure code [153] Charge Air Temp Sensor High Error 231
E-12 Failure code [154] Charge Air Temp Sensor Low Error 233
E-13 Failure code [187] Sensor Sup 2 Volt Low Error 234
E-14 Failure code [221] Ambient Air Press Sensor High Error 235
E-15 Failure code [222] Ambient Air Press Sensor Low Error 237
E-16 Failure code [227] Sensor Sup 2 Volt High Error 239
E-17 Failure code [234] Eng Overspeed 241
E-18 Failure code [238] Ne Speed Sensor Sup Volt Low Error 242
E-19 Failure code [239] Ne Speed Sensor Sup Volt High Error 243
E-20 Failure code [271] IMV Short Error 245
E-21 Failure code [272] IMV Open Error 247
E-22 Failure code [322] Injector #1 System Open/Short Error 249
E-23 Failure code [324] Injector #3 System Open/Short Error 251
E-24 Failure code [331] Injector #2 System Open/Short Error 253
E-25 Failure code [332] Injector #4 System Open/Short Error 255
E-26 Failure code [351] INJ Drive Circuit Error 257
E-27 Failure code [352] Sensor Sup 1 Volt Low Error 261
E-28 Failure code [386] Sensor Sup 1 Volt High Error 263
E-29 Failure code [415] Eng Oil press Low Speed Derate 265
E-30 Failure code [431] Idle validation switch error 266
E-31 Failure code [432] Idle validation action error 270
E-32 Failure code [435] Abnormality in engine oil pressure switch 271
E-33 Failure code [441] Battery voltage low error 272
E-34 Failure code [442] Battery voltage high error 272
E-35 Failure code [449] Rail Press Very High Error 273
E-36 Failure code [451] Rail Press Sensor High Error 275
E-37 Failure code [452] Rail Press Sensor Low Error 277
E-38 Failure code [553] Rail Press High Error 278
E-39 Failure code [559] Rail Press Low Error 279
E-40 Failure code [689] Eng Ne Speed Sensor Error 283
E-41 Failure code [731] Eng Bkup Speed Sensor Phase Error 285
E-42 Failure code [757] All Persistent Data Lost Error 286
E-43 Failure code [778] Eng Bkup Speed Sensor Error 287
E-44 Failure code [2185] Throttle Sens Sup Volt High Error 289
E-45 Failure code [2186] Throttle Sens Sup Volt Low Error 293
E-46 Failure code [2249] Rail Press Very Low Error 294
E-47 Failure code [2311] Abnormality in IMV solenoid 295
E-48 Failure code [2555] Grid Heater Relay Volt Low Error 297
E-49 Failure code [2556] Grid Heater Relay Volt High Error 298
Troubleshooting by failure code (Engine controller system) 302
Failure code [Troubleshooting tool: 111/KOMTRAX: CA111] Engine Controller Internal Error 302
Failure code [Troubleshooting tool: 115/KOMTRAX: CA115] Engine Ne and Bkup Speed Sensors Error 303
Failure code [Troubleshooting tool: 122/KOMTRAX: CA122] Charge Pressure Sensor High Error 305
Failure code [Troubleshooting tool: 123/KOMTRAX: CA123] Charge Pressure Sensor Low Error 307
Failure code [Troubleshooting tool: 131/KOMTRAX: CA131] Throttle Sensor High Error 309
Failure code [Troubleshooting tool: 132/KOMTRAX: CA132] Throttle Sensor Low Error 311
Failure code [Troubleshooting tool: 143, 415/KOMTRAX: B@BAZG] Engine Oil Pressure Drop 312
Failure code [Troubleshooting tool: 144/KOMTRAX: CA144] Coolant Temperature Sensor High Error 313
Failure code [Troubleshooting tool: 145/KOMTRAX: CA145] Coolant Temperature Sensor Low Error 315
Failure code [Troubleshooting tool: 146/KOMTRAX: B@BCNS] Engine Overheat 316
Failure code [Troubleshooting tool: 153/KOMTRAX: CA153] Charge Temperature Sensor High Error 317
Failure code [Troubleshooting tool: 154/KOMTRAX: CA154] Charge Temperature Sensor Low Error 319
Failure code [Troubleshooting tool: 187/KOMTRAX: CA187] Sensor Power Supply 2 Low Error 320
Failure code [Troubleshooting tool: 221/KOMTRAX: CA221] Ambient Pressure Sensor High Error 321
Failure code [Troubleshooting tool: 222/KOMTRAX: CA222] Ambient Pressure Sensor Low Error 323
Failure code [Troubleshooting tool: 227/KOMTRAX:CA227] Sensor Power Supply 2 High Error 325
Failure code [Troubleshooting tool: 234/KOMTRAX: CA234] Engine Over-speed 327
Failure code [Troubleshooting tool: 238/KOMTRAX: CA238] Ne Speed Sensor Power Supply Low Error 328
Failure code [Troubleshooting tool: 239/KOMTRAX: CA239] Ne Speed Sensor Power Supply High Error 329
Failure code [Troubleshooting tool: 271/KOMTRAX: CA271] IMV/PCV1 Short Circuit 331
Failure code [Troubleshooting tool: 272/KOMTRAX: CA272] IMV/PCV1 Open Circuit 333
Failure code [Troubleshooting tool: 322/KOMTRAX: CA322] Injector #1 (L#1) Open Circuit or Short Circuit 335
Failure code [Troubleshooting tool: 324/KOMTRAX: CA324] Injector #3 (L#3) Open Circuit or Short Circuit 337
Failure code [Troubleshooting tool: 331/KOMTRAX: CA331] Injector #2 (L#2) Open Circuit or Short Circuit 339
Failure code [Troubleshooting tool: 332/KOMTRAX: CA332] Injector #4 (L#4) Open Circuit or Short Circuit 341
Failure code [Troubleshooting tool: 351/KOMTRAX: CA351] Injector Drive Circuit Error 343
Failure code [Troubleshooting tool: 352/KOMTRAX: CA352] Sensor Power Supply 1 Low Error 346
Failure code [Troubleshooting tool: 386/KOMTRAX: CA386] Sensor Power Supply 1 High Error 347
Failure code [Troubleshooting tool: 428/KOMTRAX: CA428] WIF Sensor High Error 349
Failure code [Troubleshooting tool: 429/KOMTRAX: CA429] WIF Sensor Low Error 351
Failure code [Troubleshooting tool: 431/KOMTRAX: CA431] Idle Validation Switch Error 353
Failure code [Troubleshooting tool: 432/KOMTRAX: CA432] Idle Validation Process Error 357
Failure code [Troubleshooting tool: 435/KOMTRAX: CA435] Engine Oil Pressure Switch Error 358
Failure code [Troubleshooting tool: 441/KOMTRAX: CA441] Power Supply Voltage Low Error 359
Failure code [Troubleshooting tool: 442/KOMTRAX: CA442] Power Supply Voltage High Error 360
Failure code [Troubleshooting tool: 449/KOMTRAX: CA449] Common Rail Pressure High Pressure Error 2 361
Failure code [Troubleshooting tool: 451/KOMTRAX: CA451] Common Rail Pressure Sensor High Error 363
Failure code [Troubleshooting tool: 452/KOMTRAX: CA452] Common Rail Pressure Sensor Low Error 365
Failure code [Troubleshooting tool: 553/KOMTRAX: CA553] Common Rail Pressure High Pressure Error 1 366
Failure code [Troubleshooting tool: 559/KOMTRAX: CA559] Supply Pump No Pressure Feed Error 1 367
Failure code [Troubleshooting tool: 689/KOMTRAX: CA689] Engine Ne Speed Sensor Error 371
Failure code [Troubleshooting tool: 731/KOMTRAX: CA731] Engine Bkup Speed Sensor Phase Error 373
Failure code [Troubleshooting tool: 757/KOMTRAX: CA757] Engine Controller Complete Data Loss Error 374
Failure code [Troubleshooting tool: 778/KOMTRAX: CA778] Engine Bkup Speed Sensor Error 375
Failure code [Troubleshooting tool: —/KOMTRAX: CA1633] KOMNET Error 377
Failure code [Troubleshooting tool: 2185/KOMTRAX: CA2185] Throttle Sensor Power Supply High Error 379
Failure code [Troubleshooting tool: 2186/KOMTRAX: CA2186] Throttle Sensor Power Supply Low Error 381
Failure code [Troubleshooting tool: 2249/KOMTRAX: CA2249] Supply Pump No Pressure Feed Error 2 382
Failure code [Troubleshooting tool: 2311/KOMTRAX: CA2311] IMV Solenoid Error 383
Failure code [Troubleshooting tool: 2555/KOMTRAX: CA2555] Intake Air Heater Relay Open Circuit 385
Failure code [Troubleshooting tool: 2556/KOMTRAX: CA2556] Intake Air Heater Relay Short Circuit 387
50 Disassembly and assembly 390
100 Disassembly and assembly 390
How to read this manual 391
Coating materials list 392
Special tools list 395
General disassembly of engine 396
General assembly of engine 408
Disassembly and assembly procedure for fuel supply pump unit 425
Disassembly and assembly procedure for oil seal units 427
S4D95LE-3 430
CONTENTS 431
SAFETY 432
FOREWORD 434
01 GENERAL 452
GENERAL 453
SPECIFICATIONS 455
WEIGHT TABLE 456
OVERALL DRAWING 457
ENGINE PERFORMANCE CURVE 460
11 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 462
GENERAL STRUCTURE 463
General structure 463
INTAKE AND EXHAUST SYSTEM 465
Intake and exhaust system 465
Turbocharger 467
ENGINE BODY 471
Cylinder head 471
Cylinder block 475
Cylinder 478
Main revolving system 479
Crankshaft 481
Piston,piston ring and piston pin 482
Connecting rod 483
Flywheel and flywheel housing 485
Timing gear 489
Valve system 493
Camshaft 495
Rocker arm shaft,push rod and tappet 496
Valve,valve guide 497
LUBRICATION SYSTEM 498
Lubrication system chart 498
Oil pump 499
Regulator valve 501
Oil filter mount 502
Oil filter 503
FUEL SYSTEM 504
Fuel system chart 504
Fuel injection pump 505
Fuel injection nozzle 507
Fuel filter 508
COOLING SYSTEM 510
Cooling system chart 510
Water pump 511
Fan drive and thermostat 513
ELECTRICAL SYSTEM 517
Starting and charging system electrical circuit diagram 517
Alternator 518
Starting motor 519
Engine starting device 520
12 TESTING AND ADJUSTING 522
TESTING AND ADJUSTING 523
Adjusting valve clearance 523
Measuring compression pressure 525
Adjusting fuel injection pressure (Cracking pressure) 526
Testing and adjusting fuel injection timing 527
FUEL INJECTION PUMP CALIBRATION DATA 533
PERFORMANCE TEST 536
Run-in standard 536
Performance test criteria 537
TROUBLESHOOTING 540
Method of using troubleshooting charts 541
Points to remember when troubleshooting 545
S- 1 Starting performance is poor (starting always takes time) 546
S- 2 Engine does not start 547
(1) Engine does not turn 547
(2) Engine turns but no exhaust smoke comes out (fuel is not being injected) 548
(3) Exhaust smoke comes out but engine does not start (Fuel is being injected) 549
S- 3 Engine does not pick up smoothly (follow-up is poor) 550
S- 4 Engine stops during operations 551
S- 5 Engine does not rotate smoothly (hunting) 552
S- 6 Engine lacks output (no power) 553
S- 7 Exhaust smoke is black (incomplete combustion) 554
S- 8 Oil consumption is excessive or exhaust smoke is blue 555
S- 9 Oil becomes contaminated quickly 556
S-10 Fuel consumption is excessive 557
S-11 Oil is in coolant, or coolant spurts back,or coolant level goes down 558
S-12 Oil pressure caution lamp lights up (drop in oil pressure) 559
S-13 Oil level rises (water,fuel in oil) 560
S-14 Coolant temperature becomes too high (overheating) 561
S-15 Abnormal noise is made 562
S-16 Vibration is excessive 563
TESTING AND ADJUSTING TOOL LIST 564
TESTING AND ADJUSTING DATA 565
13 DISASSEMBLY AND ASSEMBLY 566
SPECIAL TOOL LIST 567
OVERALL DISASSEMBLY,ASSEMBLY 568
DISASSEMBLY 569
ASSEMBLY 581
15 REPAIR AND REPLACEMENT OF PARTS 598
CYLINDER HEAD SECTION 599
Grinding cylinder head mounting surface 599
Replacing valve guide 600
Grinding valve 601
CYLINDER BLOCK SECTION 602
Replacing camshaft bushing 602
Replacing crankshaft gear 604
Replacing cam gear 605
Replacing flywheel ring gear 606
Procedure for pressure test 607
Cylinder liner (special restoration part) 608
Machining drawing for cylinder block bore 609
Additional machining of cam journal 610
Grinding crankshaft 611
Replacing connecting rod small end bushing 612
BACK COVER 613

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