Komatsu SAA4D95LE-5, S4D95LE-3 Diesel Engine 4D95LE-BE4 (Preview)
4D95LE-BE4
00 Index and foreword
100 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 component
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
100 Specification
Outline
Specifications
General view
Weight table
Engine performance curves
10 Structure,function and maintenance standard
100 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, 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 injector
Fuel filter
Common rail
Various sensor,actuator
Various connector
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
100 Standard value table
Standard service value table for testing, adjusting, and troubleshooting
Running-in standard and performance test standard
30 Testing and adjusting
100 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
100 Troubleshooting
General information on troubleshooting
Points on troubleshooting
Failure code table
Information in troubleshooting table (E-mode)
Method of using troubleshooting charts (S-mode)
Troubleshooting for mechanical system (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
Troubleshooting for electrical system (E-mode)
E-1 Failure code [111] ECM Critical Internal Failure
E-2 Failure code [115] Eng. Ne and Bkup Speed Sensor Error
E-3 Failure code [122] Charge Air Press Sensor High Error
E-4 Failure code [123] Charge Air Press Sensor Low Error
E-5 Failure code [131] Throttle Sensor High Error
E-6 Failure code [132] Throttle Sensor Low Error
E-7 Failure code [143] Eng.Oil press.Torque Derate
E-8 Failure code [144] Coolant Temp. Sensor High Error
E-9 Failure code [145] Coolant Temp. Sensor Low Error
E-10 Failure code [146] Eng. Overheat
E-11 Failure code [153] Charge Air Temp.Sensor High Error
E-12 Failure code [154] Charge Air Temp.Sensor Low Error
E-13 Failure code [187] Sensor Sup.2 Volt. Low Error
E-14 Failure code [221] Ambient Air Press. Sensor High Error
E-15 Failure code [222] Ambient Air Press.Sensor Low Error
E-16 Failure code [227] Sensor Sup.2 Volt.High Error
E-17 Failure code [234] Eng.Overspeed
E-18 Failure code [238] Ne Speed Sensor Sup.Volt.Low Error
E-19 Failure code [239] Ne Speed Sensor Sup.Volt.High Error
E-20 Failure code [271] IMV Short Error
E-21 Failure code [272] IMV Open Error
E-22 Failure code [322] Injector #1 System Open/Short Error
E-23 Failure code [324] Injector #3 System Open/Short Error
E-24 Failure code [331] Injector #2 System Open/Short Error
E-25 Failure code [332] Injector #4 System Open/Short Error
E-26 Failure code [351] INJ. Drive Circuit Error
E-27 Failure code [352] Sensor Sup.1 Volt.Low Error
E-28 Failure code [386] Sensor Sup.1 Volt.High Error
E-29 Failure code [415] Eng.Oil press.Low Speed Derate
E-30 Failure code [431] Idle validation switch error
E-31 Failure code [432] Idle validation action error
E-32 Failure code [435] Abnormality in engine oil pressure switch
E-33 Failure code [441] Battery voltage low error
E-34 Failure code [442] Battery voltage high error
E-35 Failure code [449] Rail Press.Very High Error
E-36 Failure code [451] Rail Press.Sensor High Error
E-37 Failure code [452] Rail Press.Sensor Low Error
E-38 Failure code [553] Rail Press.High Error
E-39 Failure code [559] Rail Press.Low Error
E-40 Failure code [689] Eng.Ne Speed Sensor Error
E-41 Failure code [731] Eng.Bkup Speed Sensor Phase Error
E-42 Failure code [757] All Persistent Data Lost Error
E-43 Failure code [778] Eng.Bkup Speed Sensor Error
E-44 Failure code [2185] Throttle Sens.Sup.Volt.High Error
E-45 Failure code [2186] Throttle Sens.Sup.Volt.Low Error
E-46 Failure code [2249] Rail Press.Very Low Error
E-47 Failure code [2311] Abnormality in IMV solenoid
E-48 Failure code [2555] Grid Heater Relay Volt.Low Error
E-49 Failure code [2556] Grid Heater Relay Volt.High Error
Troubleshooting by failure code (Engine controller system)
Failure code [Troubleshooting tool: 111/KOMTRAX: CA111] Engine Controller Internal Error
Failure code [Troubleshooting tool: 115/KOMTRAX: CA115] Engine Ne and Bkup Speed Sensors Error
Failure code [Troubleshooting tool: 122/KOMTRAX: CA122] Charge Pressure Sensor High Error
Failure code [Troubleshooting tool: 123/KOMTRAX: CA123] Charge Pressure Sensor Low Error
Failure code [Troubleshooting tool: 131/KOMTRAX: CA131] Throttle Sensor High Error
Failure code [Troubleshooting tool: 132/KOMTRAX: CA132] Throttle Sensor Low Error
Failure code [Troubleshooting tool: 143, 415/KOMTRAX: B@BAZG] Engine Oil Pressure Drop
Failure code [Troubleshooting tool: 144/KOMTRAX: CA144] Coolant Temperature Sensor High Error
Failure code [Troubleshooting tool: 145/KOMTRAX: CA145] Coolant Temperature Sensor Low Error
Failure code [Troubleshooting tool: 146/KOMTRAX: B@BCNS] Engine Overheat
Failure code [Troubleshooting tool: 153/KOMTRAX: CA153] Charge Temperature Sensor High Error
Failure code [Troubleshooting tool: 154/KOMTRAX: CA154] Charge Temperature Sensor Low Error
Failure code [Troubleshooting tool: 187/KOMTRAX: CA187] Sensor Power Supply 2 Low Error
Failure code [Troubleshooting tool: 221/KOMTRAX: CA221] Ambient Pressure Sensor High Error
Failure code [Troubleshooting tool: 222/KOMTRAX: CA222] Ambient Pressure Sensor Low Error
Failure code [Troubleshooting tool: 227/KOMTRAX:CA227] Sensor Power Supply 2 High Error
Failure code [Troubleshooting tool: 234/KOMTRAX: CA234] Engine Over-speed
Failure code [Troubleshooting tool: 238/KOMTRAX: CA238] Ne Speed Sensor Power Supply Low Error
Failure code [Troubleshooting tool: 239/KOMTRAX: CA239] Ne Speed Sensor Power Supply High Error
Failure code [Troubleshooting tool: 271/KOMTRAX: CA271] IMV/PCV1 Short Circuit
Failure code [Troubleshooting tool: 272/KOMTRAX: CA272] IMV/PCV1 Open Circuit
Failure code [Troubleshooting tool: 322/KOMTRAX: CA322] Injector #1 (L#1) Open Circuit or Short Circuit
Failure code [Troubleshooting tool: 324/KOMTRAX: CA324] Injector #3 (L#3) Open Circuit or Short Circuit
Failure code [Troubleshooting tool: 331/KOMTRAX: CA331] Injector #2 (L#2) Open Circuit or Short Circuit
Failure code [Troubleshooting tool: 332/KOMTRAX: CA332] Injector #4 (L#4) Open Circuit or Short Circuit
Failure code [Troubleshooting tool: 351/KOMTRAX: CA351] Injector Drive Circuit Error
Failure code [Troubleshooting tool: 352/KOMTRAX: CA352] Sensor Power Supply 1 Low Error
Failure code [Troubleshooting tool: 386/KOMTRAX: CA386] Sensor Power Supply 1 High Error
Failure code [Troubleshooting tool: 428/KOMTRAX: CA428] WIF Sensor High Error
Failure code [Troubleshooting tool: 429/KOMTRAX: CA429] WIF Sensor Low Error
Failure code [Troubleshooting tool: 431/KOMTRAX: CA431] Idle Validation Switch Error
Failure code [Troubleshooting tool: 432/KOMTRAX: CA432] Idle Validation Process Error
Failure code [Troubleshooting tool: 435/KOMTRAX: CA435] Engine Oil Pressure Switch Error
Failure code [Troubleshooting tool: 441/KOMTRAX: CA441] Power Supply Voltage Low Error
Failure code [Troubleshooting tool: 442/KOMTRAX: CA442] Power Supply Voltage High Error
Failure code [Troubleshooting tool: 449/KOMTRAX: CA449] Common Rail Pressure High Pressure Error 2
Failure code [Troubleshooting tool: 451/KOMTRAX: CA451] Common Rail Pressure Sensor High Error
Failure code [Troubleshooting tool: 452/KOMTRAX: CA452] Common Rail Pressure Sensor Low Error
Failure code [Troubleshooting tool: 553/KOMTRAX: CA553] Common Rail Pressure High Pressure Error 1
Failure code [Troubleshooting tool: 559/KOMTRAX: CA559] Supply Pump No Pressure Feed Error 1
Failure code [Troubleshooting tool: 689/KOMTRAX: CA689] Engine Ne Speed Sensor Error
Failure code [Troubleshooting tool: 731/KOMTRAX: CA731] Engine Bkup Speed Sensor Phase Error
Failure code [Troubleshooting tool: 757/KOMTRAX: CA757] Engine Controller Complete Data Loss Error
Failure code [Troubleshooting tool: 778/KOMTRAX: CA778] Engine Bkup Speed Sensor Error
Failure code [Troubleshooting tool: —/KOMTRAX: CA1633] KOMNET Error
Failure code [Troubleshooting tool: 2185/KOMTRAX: CA2185] Throttle Sensor Power Supply High Error
Failure code [Troubleshooting tool: 2186/KOMTRAX: CA2186] Throttle Sensor Power Supply Low Error
Failure code [Troubleshooting tool: 2249/KOMTRAX: CA2249] Supply Pump No Pressure Feed Error 2
Failure code [Troubleshooting tool: 2311/KOMTRAX: CA2311] IMV Solenoid Error
Failure code [Troubleshooting tool: 2555/KOMTRAX: CA2555] Intake Air Heater Relay Open Circuit
Failure code [Troubleshooting tool: 2556/KOMTRAX: CA2556] Intake Air Heater Relay Short Circuit
50 Disassembly and assembly
100 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
S4D95LE-3
CONTENTS
SAFETY
FOREWORD
01 GENERAL
GENERAL
SPECIFICATIONS
WEIGHT TABLE
OVERALL DRAWING
ENGINE PERFORMANCE CURVE
11 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
GENERAL STRUCTURE
General structure
INTAKE AND EXHAUST SYSTEM
Intake and exhaust system
Turbocharger
ENGINE BODY
Cylinder head
Cylinder block
Cylinder
Main revolving system
Crankshaft
Piston,piston ring and piston pin
Connecting rod
Flywheel and flywheel housing
Timing gear
Valve system
Camshaft
Rocker arm shaft,push rod and tappet
Valve,valve guide
LUBRICATION SYSTEM
Lubrication system chart
Oil pump
Regulator valve
Oil filter mount
Oil filter
FUEL SYSTEM
Fuel system chart
Fuel injection pump
Fuel injection nozzle
Fuel filter
COOLING SYSTEM
Cooling system chart
Water pump
Fan drive and thermostat
ELECTRICAL SYSTEM
Starting and charging system electrical circuit diagram
Alternator
Starting motor
Engine starting device
12 TESTING AND ADJUSTING
TESTING AND ADJUSTING
Adjusting valve clearance
Measuring compression pressure
Adjusting fuel injection pressure (Cracking pressure)
Testing and adjusting fuel injection timing
FUEL INJECTION PUMP CALIBRATION DATA
PERFORMANCE TEST
Run-in standard
Performance test criteria
TROUBLESHOOTING
Method of using troubleshooting charts
Points to remember when troubleshooting
S- 1 Starting performance is poor (starting always takes time)
S- 2 Engine does not start
(1) Engine does not turn
(2) Engine turns but no exhaust smoke comes out (fuel is not being injected)
(3) Exhaust smoke comes out but engine does not start (Fuel is being injected)
S- 3 Engine does not pick up smoothly (follow-up is poor)
S- 4 Engine stops during operations
S- 5 Engine does not rotate smoothly (hunting)
S- 6 Engine lacks output (no 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 caution lamp lights up (drop in oil pressure)
S-13 Oil level rises (water,fuel in oil)
S-14 Coolant temperature becomes too high (overheating)
S-15 Abnormal noise is made
S-16 Vibration is excessive
TESTING AND ADJUSTING TOOL LIST
TESTING AND ADJUSTING DATA
13 DISASSEMBLY AND ASSEMBLY
SPECIAL TOOL LIST
OVERALL DISASSEMBLY,ASSEMBLY
DISASSEMBLY
ASSEMBLY
15 REPAIR AND REPLACEMENT OF PARTS
CYLINDER HEAD SECTION
Grinding cylinder head mounting surface
Replacing valve guide
Grinding valve
CYLINDER BLOCK SECTION
Replacing camshaft bushing
Replacing crankshaft gear
Replacing cam gear
Replacing flywheel ring gear
Procedure for pressure test
Cylinder liner (special restoration part)
Machining drawing for cylinder block bore
Additional machining of cam journal
Grinding crankshaft
Replacing connecting rod small end bushing
BACK COVER
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