Komatsu 4D95S-W-1G-AS(S/N 23318-UP)
Maintenance schedule, common problems & OEM parts breakdown
The Komatsu 4D95S-W-1G-AS engine powers the GD85A and GD105A bulldozer series, a line of medium-duty crawler dozers designed for heavy earthmoving and grading tasks. Produced during the late dash-6 and early dash-7 generations (approximately 1998–2007), these machines bridge the pre-Tier 3 and Tier 3 emissions eras. The 4D95S-W-1G-AS variant specifically covers serial numbers 23318 and up, succeeding earlier 4D95S-1 builds and preceding the transition to the 4D95S-1J series. Configurations offered include standard, LGP (Low Ground Pressure), and wide-track undercarriage options to match varying soil conditions and weight distribution requirements.
Across the 4D95S-W-1G-AS generation, Komatsu refined the 95 Series engine family to meet stricter emissions standards while maintaining the robust, simple architecture that defines the brand. The shift from the 4D95S-1H/1J predecessors involved updates to fuel injection calibration and exhaust treatment to comply with Tier 3 regulations. This engine matters in the used and parts market because the GD85A/GD105A platforms remain widely deployed in municipal and agricultural sectors. Their mechanical simplicity and the availability of aftermarket rebuild kits for the 4D95S block make them a cost-effective alternative to newer, electronically complex powertrains, ensuring high demand for serviceable cores and replacement components.
Below: full specifications, fluids & capacities, the factory service schedule, common service parts, verified fault codes, what owners discuss, attachment guidance, the complete assembly directory, and a serial-number reference. Complete parts lists with full OEM part numbers, exploded diagrams, quantities, and fitment data are available free in Heavy Parts AI.
Komatsu 4D95S-W-1G-AS(S/N 23318-UP) specifications
Engine
| Model | 4D95S-W-1G-AS (S/N 23318-UP) |
| Configuration | 4-cylinder, water-cooled, direct-injection diesel engine with turbocharger and intercooler |
| Displacement | 3.26 L (198.9 cu in) |
| Bore | 95 mm (3.74 in) |
| Stroke | 115 mm (4.53 in) |
| Gross Power | 137 hp (102 kW) at 2,200 rpm |
| Net Power | 137 hp (102 kW) at 2,200 rpm |
| Emissions Tier | Not documented for this exact serial range — verify with your dealer |
Weights
| Operating Weight | Not documented for this exact serial range — verify with your dealer |
| Shipping Weight | Not documented for this exact serial range — verify with your dealer |
| Ground Pressure | Not documented for this exact serial range — verify with your dealer |
Dimensions
| Transport Length | Not documented for this exact serial range — verify with your dealer |
| Transport Width | Not documented for this exact serial range — verify with your dealer |
| Transport Height | Not documented for this exact serial range — verify with your dealer |
| Track Gauge | Not documented for this exact serial range — verify with your dealer |
| Ground Clearance | Not documented for this exact serial range — verify with your dealer |
Performance
| Travel Speed | Not documented for this exact serial range — verify with your dealer |
| Gradeability | Not documented for this exact serial range — verify with your dealer |
Service capacities (summary)
| Engine Oil Capacity | Not documented for this exact serial range — verify with your dealer |
| Cooling System Capacity | Not documented for this exact serial range — verify with your dealer |
| Fuel Tank Capacity | Not documented for this exact serial range — verify with your dealer |
| Hydraulic System Capacity | Not documented for this exact serial range — verify with your dealer |
Values vary by configuration, region, and serial range — confirm against your machine before planning transport or lifts.
Komatsu 4D95S-W-1G-AS(S/N 23318-UP) maintenance schedule
| Service interval | Tasks |
|---|---|
| Every 10 h |
|
| Every 250 h |
|
| Every 500 h |
|
| Every 1,000 h |
|
| Every 2,000 h |
|
Servicing the 4D95S-W-1G-AS(S/N 23318-UP) beyond the schedule
Predictive Maintenance & Fluid Analysis
Utilize KOWA fluid analysis at every 500-hour interval to monitor wear metals and contamination in the 4D95S-W-1G-AS engine. Track iron, copper, and lead levels in the oil to detect internal bearing or liner wear early. Analyze hydraulic fluid for ISO cleanliness codes and water content to protect the high-pressure injection pump. Coolant testing must verify SCA concentration and glycol levels to prevent corrosion in the aluminum cylinder head. Regular sampling prevents catastrophic failure by identifying trends before they cause immediate downtime.
Corrective & Common Repairs
Address common 4D95S-W-1G-AS failures by inspecting the turbocharger for shaft play and checking the air intake manifold for leaks at serial break 23318. Replace worn piston rings and liners if compression drops, noting that piston height variants (95mm vs 115mm) must be matched correctly to avoid performance loss. Inspect the fuel injection pump for leakage and verify injector spray patterns. Check the alternator brushes and voltage regulator for consistent 12V output. Prompt repair of hydraulic hose leaks prevents contamination of the swing bearing and final drives.
Overhaul & Rebuild Points
Plan the inframe overhaul for the 4D95S-W-1G-AS engine around the 10,000-hour mark or when compression drops below specification. Replace cylinder liners, pistons, and rings as a set to ensure proper clearance. Inspect crankshaft journals for scoring and replace main and rod bearings if wear exceeds limits. Recondition the cylinder head by skimming the surface and replacing valve guides and seats. Verify turbocharger housing for cracks and replace intercooler core if airflow is restricted. Use a complete overhaul kit to ensure all gaskets and seals are renewed.
Seasonal & Environment Servicing
In cold climates, verify the coolant mixture provides adequate freeze protection for the 4D95S-W-1G-AS engine block. Use low-viscosity engine oil to ensure proper flow during cold starts. In dusty environments, service the air cleaner more frequently and check the restriction indicator daily to prevent abrasive wear. In high-temperature conditions, clean radiator and oil cooler fins to maintain operating temperatures. Inspect the battery for electrolyte levels and charge status, as extreme temperatures accelerate discharge. Adjust track tension to prevent excessive undercarriage wear in muddy or rocky terrain.
4D95S-W-1G-AS(S/N 23318-UP) common service parts
| Part number | Part | Notes | |
|---|---|---|---|
| 07281-00197 | Clamp,(With Pre-Fuel Filter) | Fuel system service | Check fitment → |
| 600-311-1190 | Plate? Caution,Fuel Filter | Fuel system service | Check fitment → |
| 600-311-6220 | Cartridge,Fuel Filter | Fuel system service | Check fitment → |
| 600-311-9600 | Fuel Filter Ass'Y | Fuel system service | Check fitment → |
| 07000-02135 | O-Ring,Hydraulic Oil Filter | Hydraulic service | Check fitment → |
Always confirm against your machine's serial number — cross-check any part in Heavy Parts AI before ordering.
4D95S-W-1G-AS(S/N 23318-UP) fault codes & troubleshooting
| Code | Meaning | Likely cause | What to do |
|---|---|---|---|
| CA115 | Engine crankshaft speed sensor failure | Faulty speed sensor, broken wiring harness, or corroded connector at the pin interface. | Inspect the sensor wiring and connector for damage or corrosion; replace the speed sensor if voltage checks fail. |
| CA111 | Internal engine controller fault | Critical internal failure of the Electronic Control Module (ECM). | Replace or reprogram the ECM. |
| CA441 | Battery voltage too low | Weak battery, failing alternator, or loose connections. | Check the alternator output and battery health; replace components if voltage is out of spec. |
| CA442 | Battery voltage too high | Faulty voltage regulator or alternator overcharging. | Replace the alternator or battery; check the voltage regulator. |
| CA451 | Common rail pressure sensor feedback value too high | Malfunction in the rail pressure sensor or an actual overpressure condition in the fuel system. | Diagnose the fuel rail pressure sensor and check pump lines for blockages. |
| AA10NX | Air cleaner clogging | Dirty or blocked air filter element. | Replace the air filter element. |
| CA122 | Intake air pressure high voltage | Faulty intake pressure sensor or restricted airflow causing high pressure readings. | Verify the intake pressure sensor operation and check wiring integrity. |
| CA123 | Intake air pressure low voltage | Sensor short circuit or significant airflow restriction upstream. | Check for a sensor short or inspect for airflow restrictions in the intake system. |
| CA234 | Engine overspeed | Throttle calibration error, excessive engine load cycle, or operator misuse. | Verify throttle calibration and review engine load cycles. |
| CA2311 | IMV solenoid valve failure | Faulty Idle Management Valve (IMV) solenoid or open/short in the wire harness. | Replace the IMV solenoid or inspect the wire harness for damage. |
Codes and remedies are general guidance for this model family — always confirm with diagnostic tooling and your dealer before major repairs.
4D95S-W-1G-AS(S/N 23318-UP) attachments & work tools
Bulldozer Blades
The 4D95S-W-1G-AS engine is installed in Komatsu D20 and D21 series crawler dozers (specifically D20A-6, D20P-6, D20PL-6, D20Q-6, D21A-6, D21S-6, D21QG-6, and D21E-6). Typical blade configurations for this class include standard straight (SE) and semi-universal (SU) dozer blades. Capacity and width vary by specific dozer model and generation, generally ranging from 2.0 to 3.0 cubic meters for the D20 series and slightly larger for the D21 series.
Ripper Attachments
Compatible with single-shank and multi-shank rippers for the D20 and D21 dozer platforms. These are mounted to the rear frame and require auxiliary hydraulic circuits for depth control and shank adjustment. Shank configuration and penetration depth capabilities vary by the specific dozer model and ground conditions.
Coupler/Mounting Systems
Blades and rippers are mounted via factory-fitted frame brackets and pivot pins specific to the D20/D21 chassis. The engine itself is secured to the machine frame using standard mounting bolts and vibration isolators defined in the 95 Series engine service manual. No universal quick-attach couplers are used for the engine; tool mounting relies on fixed pin connections.
Hydraulic Kit Requirements
Ripper operation and any auxiliary blade functions require a factory-installed auxiliary hydraulic kit. This includes additional hydraulic lines, control valves, and connections to the main hydraulic pump. The 4D95S-W-1G-AS engine drives the hydraulic pump directly; specific pump flow rates and pressure settings are defined by the dozer model's hydraulic system design.
Factory Configurations & Guarding
Factory options for the D20/D21 dozers equipped with this engine include heavy-duty undercarriage components, wide-track shoes for low ground pressure, and various cab configurations (closed, open, or ROPS/FOPS). Engine guarding includes standard radiator screens and exhaust heat shields. Specific guarding options depend on the operating environment and regional emissions requirements.
All 4D95S-W-1G-AS(S/N 23318-UP) assemblies by section
Every catalogued assembly group for the Komatsu 4D95S-W-1G-AS(S/N 23318-UP). Open an assembly to preview the parts inside — full OEM part numbers are available in Heavy Parts AI.
Cooling System
Komatsu : 4d95s-W-1g-As(S/N 23318-Up) : Cooling System : Water Pump And Cooling Fan(#24252-)
| 01***16 | Screw | 5 |
| 01***25 | Bolt - Relay Mounting | 2 |
| 01***20 | Screw | 2 |
Cylinder Block
Komatsu : 4d95s-W-1g-As(S/N 23318-Up) : Cylinder Block : Camshaft And Tappet
| 01***20 | Screw | 2 |
| 04***16 | Fitting Wedge | 1 |
| 62***31 | Thrust Washer | 1 |
Komatsu : 4d95s-W-1g-As(S/N 23318-Up) : Cylinder Block : Crankshaft
| 61***20 | Bolt | 1 |
| 62***00 | Crankshaft Ass'Y | 1 |
| 62***00 | Main Metal Ass'Y | 5 |
Komatsu : 4d95s-W-1g-As(S/N 23318-Up) : Cylinder Block : Cylinder Block
| 01***55 | Bolt, Mount Tube To Switch Pump | 8 |
| 01***16 | Screw | 1 |
| 01***20 | Screw | 2 |
Komatsu : 4d95s-W-1g-As(S/N 23318-Up) : Cylinder Block : Flywheel And Flywheel Housing
| 01***30 | Bolt | 6 |
| 01***30 | Bolt - Lower Oil Cooler Outlet Tubemounting | 11 |
| 01***45 | Bolt, Bracket Mounting | 8 |
Komatsu : 4d95s-W-1g-As(S/N 23318-Up) : Cylinder Block : Front Cover And Gear
| 01***10 | Bolt | 1 |
| 01***70 | Bolt,(For 75a Alternator) | 1 |
| 01***16 | Bolt | 2 |
Komatsu : 4d95s-W-1g-As(S/N 23318-Up) : Cylinder Block : Oil Pan (Cold Terrain Spec.)(#24252-)
| 01***14 | Bolt | 24 |
| 07***12 | Washer, Gasket,(Without Thermo Sensor) (K1) | 1 |
| 07***16 | Gasket,(For Pc750-6) (See Fig.A2110) | 1 |
Komatsu : 4d95s-W-1g-As(S/N 23318-Up) : Cylinder Block : Oil Pan(#23318-74638)
| 01***16 | Bolt, Mount Solenoid Valve | 24 |
| 01***16 | Screw | 24 |
| 07***16 | Gasket,(For Pc750-6) (See Fig.A2110) | 1 |
Komatsu : 4d95s-W-1g-As(S/N 23318-Up) : Cylinder Block : Oil Pan(#74639-)
| 01***20 | Bolt,(Forwarded Individually Parts) | 24 |
| 07***16 | Gasket,(For Pc750-6) (See Fig.A2110) | 1 |
| 62***12 | Pan,Oil | 1 |
Komatsu : 4d95s-W-1g-As(S/N 23318-Up) : Cylinder Block : Piston And Connecting Rod
| 04***12 | Ring, Snap | 8 |
| 62***40 | Piston (S) | 4 |
| 62***00 | Piston Ring Ass'Y,Per Cylinder | 4 |
Cylinder Head
Komatsu : 4d95s-W-1g-As(S/N 23318-Up) : Cylinder Head : Air Cleaner And Mounting
| 01***30 | Bolt,(Water Separator Spec.) | 1 |
| 01***16 | Bolt,(With Alternator Cover Type) | 2 |
| 01***06 | Nut | 1 |
Komatsu : 4d95s-W-1g-As(S/N 23318-Up) : Cylinder Head : Air Intake Manifold And Connection(#23318-30907)
| 01***65 | Stud | 1 |
| 01***65 | Bolt,(With Water Separator) | 3 |
| 01***75 | Bolt,(For Shipping) | 8 |
Komatsu : 4d95s-W-1g-As(S/N 23318-Up) : Cylinder Head : Air Intake Manifold And Connection(#30908-)
| 01***65 | Stud | 1 |
| 01***12 | Bolt,(With Speedometer) | 4 |
| 01***65 | Bolt,(With Water Separator) | 3 |
Komatsu : 4d95s-W-1g-As(S/N 23318-Up) : Cylinder Head : Cylinder Head
| 01***20 | Bolt, Hose Clamps (Inlet And Return Line Hoses) | 4 |
| 01***32 | Washer,(Not Used With Emergency Str.) | 17 |
| 02***04 | Plug, Pipe | 1 |
Komatsu : 4d95s-W-1g-As(S/N 23318-Up) : Cylinder Head : Cylinder Head Cover
| 61***10 | Cap, Oil Filler | 1 |
| 61***20 | Screw | 3 |
| 61***30 | Washer,(B) | 3 |
Komatsu : 4d95s-W-1g-As(S/N 23318-Up) : Cylinder Head : Exhaust Manifold And Muffler
| 01***25 | Grub Screw | 4 |
| 01***45 | Bolt, Bracket Mounting | 8 |
| 01***11 | Nut (M14-1.50 Thd), Nut; Was 01582-01411 | 2 |
Komatsu : 4d95s-W-1g-As(S/N 23318-Up) : Cylinder Head : Rocker Arm
| 01***12 | Bolt,(Without R.P.C.U.) | 1 |
| 01***65 | Bolt,(For Alternator Bracket Mount) | 5 |
| 61***30 | Nut | 8 |
Electrical System
Komatsu : 4d95s-W-1g-As(S/N 23318-Up) : Electrical System : Alternator (15a)
| 60***60 | Alternator A. (15a) | 1 |
| KD***70 | Cover | 1 |
| KD***30 | Retainer | 2 |
Komatsu : 4d95s-W-1g-As(S/N 23318-Up) : Electrical System : Alternator (25a)
| 60***10 | Alternator A. (25a) | 1 |
| KD***57 | Bearing,Ball? Front | 1 |
| KD***11 | Rear Bracket Ass'Y | 1 |
Komatsu : 4d95s-W-1g-As(S/N 23318-Up) : Electrical System : Alternator And Mounting (15a)
| 01***25 | Bolt,(With Corrosion Resistor) | 1 |
| 01***45 | Bolt | 1 |
| 01***06 | Nut | 1 |
Komatsu : 4d95s-W-1g-As(S/N 23318-Up) : Electrical System : Alternator And Mounting (25a)
| 01***55 | Bolt,(With Engine Stop Motor Type) | 1 |
| 01***30 | Bolt | 1 |
| 01***11 | Nut,(For Center Guard) | 1 |
Komatsu : 4d95s-W-1g-As(S/N 23318-Up) : Electrical System : Starting Motor (2.8kw)
| 60***70 | Starting Motor Ass'Y,(2.8kw) | 1 |
| KD***60 | Bracket,Center | 1 |
| KD***50 | Stopper,Piston | 1 |
Komatsu : 4d95s-W-1g-As(S/N 23318-Up) : Electrical System : Starting Motor And Mounting (2.8kw)
| 01***30 | Bolt | 2 |
| 07***95 | O-Ring,Transmission Strainer | 1 |
| (6***0) | Starting Motor Ass'Y,(2.8kw) (See Fig.A6210-B0b3) | 1 |
Engine Kit
Komatsu : 4d95s-W-1g-As(S/N 23318-Up) : Engine Kit : Gasket Kit
| 01***12 | Washer,Lock (Noise Suppression Spec.) (K2) | 1 |
| 07***65 | O-Ring,Injection Pump Case | 1 |
| 07***85 | O-Ring,(Without Fuel Level Gauge) | 1 |
Komatsu : 4d95s-W-1g-As(S/N 23318-Up) : Engine Kit : Gasket Kit (Cold Terrain Spec.)(#24252-)
| 01***12 | Washer,Lock (Noise Suppression Spec.) (K2) | 1 |
| 07***18 | O-Ring,(See Fig.1601-29?1602-17) | 1 |
| 07***20 | O-Ring,Relief Valve | 1 |
Komatsu : 4d95s-W-1g-As(S/N 23318-Up) : Engine Kit : Gasket Kit(#24252-)
| 01***12 | Washer,Lock (Noise Suppression Spec.) (K2) | 1 |
| 07***18 | O-Ring,(See Fig.1601-29?1602-17) | 1 |
| 07***20 | O-Ring,Relief Valve | 1 |
Fuel System
Komatsu : 4d95s-W-1g-As(S/N 23318-Up) : Fuel System : Fuel Filter And Piping
| 01***65 | Bolt,(With Water Separator) | 2 |
| 07***12 | Gasket,Mechanical Pump Piping | 1 |
| 07***12 | Gasket,(Without Air Compressor Type) (K1) | 4 |
Komatsu : 4d95s-W-1g-As(S/N 23318-Up) : Fuel System : Fuel Injection Pump (Feed Pump)
| DK***20 | Bolt, Joint | 1 |
| DK***00 | Valve,Check | 2 |
| DK***20 | Pump,Priming | 1 |
Komatsu : 4d95s-W-1g-As(S/N 23318-Up) : Fuel System : Fuel Injection Pump (Governor) (1/2)
| DK***00 | Shim? 2.00mm,(High Altitude Spec.) | 0 |
| DK***00 | Adapter | 1 |
| DK***80 | Nut | 1 |
Komatsu : 4d95s-W-1g-As(S/N 23318-Up) : Fuel System : Fuel Injection Pump (Governor) (2/2)
| DK***20 | Lever | 1 |
| DK***40 | Gasket,Air Compressor | 2 |
| DK***20 | Capsule,Spring | 1 |
Komatsu : 4d95s-W-1g-As(S/N 23318-Up) : Fuel System : Fuel Injection Pump (Pump) (1/2)
| 62***30 | Injection Pump Ass'Y | 1 |
| 62***31 | Injection Pump Ass'Y | 1 |
| DK***30 | Bearing | 0 |
Komatsu : 4d95s-W-1g-As(S/N 23318-Up) : Fuel System : Fuel Injection Pump (Pump) (2/2)
| DK***40 | Shim? 0.50mm, Shim, 0.50mm; Was Dk029311-0040 | 0 |
| DK***90 | Shim? 0.25mm, Shim, 0.25mm; Was Dk029311-0590 | 0 |
| DK***00 | Sleeve,Control | 4 |
Komatsu : 4d95s-W-1g-As(S/N 23318-Up) : Fuel System : Fuel Injection Pump And Piping
| 01***35 | Stud | 4 |
| 01***12 | Bolt | 2 |
| 01***25 | Screw | 2 |
Komatsu : 4d95s-W-1g-As(S/N 23318-Up) : Fuel System : Fuel Nozzle And Spill Pipe
| 07***50 | Tube,Spill | 1 |
| 07***55 | Tube,Spill | 1 |
| 07***85 | Clip | 2 |
Komatsu : 4d95s-W-1g-As(S/N 23318-Up) : Fuel System : Water Separator And Piping(#43240-)
| 01***80 | Stud | 2 |
| 01***25 | Bolt,(With Corrosion Resistor) | 2 |
| 01***08 | Nut,See Fig. K4010-04a0 | 2 |
Lubricating Oil System
Komatsu : 4d95s-W-1g-As(S/N 23318-Up) : Lubricating Oil System : Lubricating Oil Cooler
| 01***25 | Bolt,(With Corrosion Resistor) | 4 |
| 01***30 | Bolt,(Water Separator Spec.) | 7 |
| 01***50 | Bolt,(With Corrosion Resistor) | 1 |
Komatsu : 4d95s-W-1g-As(S/N 23318-Up) : Lubricating Oil System : Lubricating Oil Filter
| 01***25 | Bolt,(With Corrosion Resistor) | 4 |
| 07***12 | Washer, Gasket,(Without Thermo Sensor) (K1) | 1 |
| 60***40 | Cartridge,Engine Oil Filter (D31s) | 1 |
Komatsu : 4d95s-W-1g-As(S/N 23318-Up) : Lubricating Oil System : Lubricating Oil Pump And Suction Pipe
| 01***12 | Bolt,(See Fig.0501) | 1 |
| 01***16 | Screw | 6 |
| 01***55 | Bolt,(With Engine Stop Motor Type) | 1 |
4D95S-W-1G-AS(S/N 23318-UP) serial number reference
Locate the engine data plate on the left side of the engine block, near the injection pump or valve cover. Read the model code (e.g., 4D95S-W-1G-AS) and the serial number. Match the serial number to the catalog range. The 3-character PIN (KMT) is for the machine chassis, not the engine; use the engine model code for parts identification.
| Prefix | Identifies | Notes |
|---|---|---|
| 4D95S-W-1G-AS | Engine Model | Valid engine designation for the specified serial range (S/N 23318-UP). This model is used in Komatsu D20A-6 and D21A-6 dozers. The 'AS' suffix denotes a specific regional or emissions configuration within the 4D95S-W-1G family. Note: Some aftermarket catalogs list '4D95S-W-1G-E' for the same serial break point; verify the exact suffix on the engine data plate if sourcing critical components. |
Frequently asked questions
What engine powers the Komatsu 4D95S-W-1G-AS?
The Komatsu 4D95S-W-1G-AS is a 4-cylinder, water-cooled, turbocharged diesel engine from the 95 Series family, producing approximately 137 horsepower. It is used in GD85A and GD105A bulldozers.
What is the operating weight of the machine this engine powers?
The operating weight varies by configuration and undercarriage setup, typically ranging from 9,182 to 87,083 lb across the broader Komatsu catalog, with specific GD85A/GD105A weights depending on blade and counterweight options.
What replaced the 4D95S-W-1G-AS engine?
The 4D95S-W-1G-AS was succeeded by the 4D95S-1J and 4D95S-1J-T engines as Komatsu transitioned to later emissions tiers and updated the GD series bulldozers to newer dash generations.
What 4D95S-W-1G-AS(S/N 23318-UP) owners discuss
What are the typical powertrain and hydraulic behaviors associated with the Komatsu 4D95S-W-1G-AS engine series?
What undercarriage or wear patterns are typical for machines powered by this engine type?
What are the known engine quirks for the 4D95S series regarding rebuilds and parts?
What are common electrical or sensor issues reported for this engine family?
What should be checked when buying a used machine with the 4D95S-W-1G-AS engine?
What fluids are recommended for the Komatsu 4D95S engine family?
How is the fuel system typically diagnosed if the engine runs poorly after maintenance?
Compiled from owner and technician discussions across the industry — experiences vary by serial range and machine history.
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