KOMATSU SAA4D95LE-5-A, S4D95LE-3 DIESEL ENGINE LIFT TRUCK SERVICE SHOP MANUAL

KOMATSU SAA4D95LE-5-A, S4D95LE-3 DIESEL ENGINE LIFT TRUCK SERVICE SHOP MANUAL
LANGUAGE: ENGLISH
FORMAT: PDF
PAGES: 503
FILE SIZE: 47.7MB

MODEL COVERED:

SAA4D95LE-5-A DIESEL ENGINE

- FD40Z-10 — M250-133001 AND UP

- FD35-10 — M252-133001 AND UP

- FD40-10 — M252-133001 AND UP

- FD45-10 — M252-133001 AND UP

- FD50A-10 — M252-133001 AND UP

- FD60-10 — M248-55001 AND UP

- FD70-10 — M248-55001 AND UP

- FD80-10 — M248-55001 AND UP

S4D95LE-3 DIESEL ENGINE

- 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

PART NO:

4D95LE-BE2
 

CONTENTS:

00 – INDEX AND FOREWORD

- Index and Foreword

- Composition of Shop Manual

- Table of Contents

- Safety Notice

- How to Read the Shop Manual

- Explanation of Terms for Maintenance Standard

- Handling of Electric Equipment and Hydraulic Components

- Handling of Connectors Newly Used for Engines

- How to Read Electric Wire Code

- Precautions When Carrying Out Operation

- Method of Disassembling and Connecting Push-Pull Type Coupler

- Standard Tightening Torque Table

- Conversion Table

01 – SPECIFICATION

- Specification

- Outline

- Specifications

- General View

- Weight Table

- Engine Performance Curves

10 – STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

General Structure

- General Structure

Air Intake and Exhaust System

- Air Intake and Exhaust Unit

- Turbocharger

Engine Unit

- Cylinder Head

- Cylinder Block

- Cylinder

- Main Moving Parts

- Crankshaft

- Camshaft

- Piston, Piston Ring and Piston Pin

- Connecting Rod

- Flywheel and Flywheel Housing

- Timing Gear

- Valve System

- Valve and Valve Guide

- Rocker Arm Shaft, Push Rod and Tappet

Lubrication System

- Lubrication System Diagram

- Oil Pump

- Regulator Valve

- Oil Filter

Fuel System

- Fuel System Diagram

- Supply Pump

- Fuel Injection Nozzle

- Fuel Filter

- Common Rail

- Various Sensors

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

20 – STANDARD VALUE TABLE

- Standard Value Table

- Standard Service Value Table for Testing, Adjusting and Troubleshooting

- Running-in Standard and Performance Test Standard

30 – TESTING AND ADJUSTING

- Testing and Adjusting Tools List

- Testing Exhaust Temperature

- Adjusting Valve Clearance

- Testing Compression Pressure

- Testing Blow-by Pressure

- Testing Oil Pressure

- Handling Fuel System Parts

- Releasing Residual Pressure in Fuel System

- Testing Fuel Pressure

- Reduced Cylinder Mode Operation

- No-injection Cranking

- Testing Leakage from Pressure Limiter and Return Rate from Injector

- Bleeding Air from Fuel Circuit

- Testing Fuel System for Leakage

- Testing and Adjusting Alternator Belt Tension

- Handling Controller Voltage Circuit

- Functions of Troubleshooting Tool and Check of Failure Code

40 – TROUBLESHOOTING

General Troubleshooting

- General Information on Troubleshooting

- Points on Troubleshooting

- Failure Code Table

- Information in Troubleshooting Table (E-mode)

- Method of Using Troubleshooting Charts (S-mode)

Mechanical System Troubleshooting (S-mode)

- S-1 Starting Performance Is Poor

- S-2 Engine Does Not Start

- S-3 Engine Does Not Pick Up Smoothly

- S-4 Engine Stops During Operations

- S-5 Engine Does Not Rotate Smoothly

- S-6 Engine Lacks Output (or Lacks Power)

- S-7 Exhaust Smoke Is Black (Incomplete Combustion)

- S-8 Oil Consumption Is Excessive (or Exhaust Smoke Is Blue)

- S-9 Oil Becomes Contaminated Quickly

- S-10 Fuel Consumption Is Excessive

- S-11 Oil Is in Coolant (or Coolant Spurts Back or Coolant Level Goes Down)

- S-12 Oil Pressure Drops

- S-13 Oil Level Rises (Entry of Coolant or Fuel)

- S-14 Coolant Temperature Becomes Too High (Overheating)

- S-15 Abnormal Noise Is Made

- S-16 Vibration Is Excessive

Electrical System Troubleshooting (E-mode)

- E-1 ECM Critical Internal Failure

- E-2 Engine Backup Speed Sensor Error

- E-3 Charge Air Pressure Sensor High Error

- E-4 Charge Air Pressure Sensor Low Error

- E-5 Throttle Sensor High Error

- E-6 Throttle Sensor Low Error

- E-7 Engine Oil Pressure Torque Derate

- E-8 Coolant Temperature Sensor High Error

- E-9 Coolant Temperature Sensor Low Error

- E-10 Engine Overheat

- E-11 Charge Air Temperature Sensor High Error

- E-12 Charge Air Temperature Sensor Low Error

- E-13 Sensor Supply 2 Volt Low Error

- E-14 Ambient Air Pressure Sensor High Error

- E-15 Ambient Air Pressure Sensor Low Error

- E-16 Sensor Supply 2 Volt High Error

- E-17 Engine Overspeed

- E-18 Engine Speed Sensor Supply Voltage Low Error

- E-19 Engine Speed Sensor Supply Voltage High Error

- E-20 IMV Short Error

- E-21 IMV Open Error

- E-22 Injector #1 System Open/Short Error

- E-23 Injector #3 System Open/Short Error

- E-24 Injector #2 System Open/Short Error

- E-25 Injector #4 System Open/Short Error

- E-26 Injector Drive Circuit Error

- E-27 Sensor Supply 1 Volt Low Error

- E-28 Sensor Supply 1 Volt High Error

- E-29 Engine Oil Pressure Low Speed Derate

- E-30 Idle Validation Switch Error

- E-31 Idle Validation Action Error

- E-32 Abnormality in Engine Oil Pressure Switch

- E-33 Battery Voltage Low Error

- E-34 Battery Voltage High Error

- E-35 Rail Pressure Very High Error

- E-36 Rail Pressure Sensor High Error

- E-37 Rail Pressure Sensor Low Error

- E-38 Rail Pressure High Error

- E-39 Rail Pressure Low Error

- E-40 Engine Backup Speed Sensor Error

- E-41 Engine Backup Speed Sensor Phase Error

- E-42 All Persistent Data Lost

- E-43 Engine Backup Speed Sensor Error

- E-44 Throttle Sensor Supply Voltage High Error

- E-45 Throttle Sensor Supply Voltage Low Error

- E-46 Rail Pressure Very Low Error

- E-47 Abnormality in IMV Solenoid

- E-48 Grid Heater Relay Voltage Low Error

- E-49 Grid Heater Relay Voltage High Error

50 – DISASSEMBLY AND ASSEMBLY

- How to Read This Manual

- Coating Materials List

- Special Tools List

- General Disassembly of Engine

- General Assembly of Engine

- Disassembly and Assembly Procedure for Fuel Supply Pump Unit

- Disassembly and Assembly Procedure for Oil Seal Units

The Komatsu SAA4D95LE-5-A and S4D95LE-3 Diesel Engine Lift Truck Service Shop Manual is a detailed technical workshop reference covering engine specifications, construction, operating principles, maintenance standards, testing, adjustment, troubleshooting, disassembly and assembly procedures. It provides comprehensive information on major engine components and systems, including the cylinder head, cylinder block, crankshaft, camshaft, pistons, connecting rods, timing gears, valve system, air intake and exhaust system, turbocharger, lubrication system, fuel system, common rail, cooling system and electrical equipment. The manual also includes standard service values, testing procedures for compression and oil pressure, fuel system inspection, valve clearance adjustment, alternator belt tension adjustment, mechanical troubleshooting guidance and electrical failure code diagnosis. Its troubleshooting section covers common engine problems such as starting difficulties, poor performance, excessive smoke, abnormal noise, overheating, oil pressure issues and electrical sensor or injector faults. It also provides guidance for engine disassembly and assembly, supported by special tool information and component-specific procedures. This manual covers the SAA4D95LE-5-A engine fitted to Komatsu FD40Z-10, FD35-10, FD40-10, FD45-10, FD50A-10, FD60-10, FD70-10 and FD80-10 forklifts, as well as the S4D95LE-3 engine fitted to FD40ZY-10, FD35Y-10, FD40Y-10, FD45Y-10 and FD50AY-10 models. An essential technical resource for Komatsu forklift technicians, diesel mechanics, service engineers, repair workshops and maintenance professionals involved in engine inspection, servicing, fault diagnosis and overhaul.