Pulling a Komatsu S4D95LE-3 down to a bare block and putting it back to factory clearances is what the 166 pages of shop manual SM206 exist for, covering six designations of this four-cylinder diesel. Anyone hunting a Komatsu S4D95LE-3, CX50, FD40ZY, FD35Y, FD40Y, FD45Y service manual PDF gets the real book here: injection pump calibration data, compression test procedures, and a starting and charging circuit diagram with every wire coded. Troubleshooting charts walk from symptom to cause, and the repair section covers valve guide replacement, crankshaft grinding, and cylinder liner work. Check turbocharger rotor end play against the 0.010 to 0.076 mm standard before you condemn the cartridge, then pull your head bolts down in two steps: 68.6 N-m first, 107.8 N-m final. Every day apart on the stand is lost time. Buy this once and the bookmarked, text-searchable PDF stays yours for the life of the engine.
What's Inside This Komatsu S4D95LE-3 Engine (CX50 Series) Manual
| System | Pages | Key Topics |
|---|
| Service Manual | 1 | |
| Safety | 2-3 | General Precautions, Precautions During Work |
| General | 22-30 | Specifications, Overall Drawing, Engine Performance Curve |
| Structure, Function and Maintenance Standard | 31-82 | General Structure, Intake and Exhaust System, Turbocharger, Cylinder Head, Cylinder Block, Main Revolving System, Lubrication System Chart, Fuel System Chart |
| Testing and Adjusting | 83-97 | Adjusting Valve Clearance, Measuring Compression Pressure, Adjusting Fuel Injection Pressure, Testing and Adjusting Fuel Injection Timing, Fuel Injection Pump Calibration Data |
| Troubleshooting | 98-122 | Method of Using Troubleshooting Charts |
| Disassembly and Assembly | 123-152 | Special Tool List, Overall Disassembly, Assembly |
| Repair and Replacement of Parts | 153-166 | Cylinder Head Mounting Surface, Valve Guide, Valve Grinding, Camshaft Bushing, Crankshaft Gear, Connecting Rod Small End Bushing |
Quick Reference Specifications
| Specification | Value | Page |
|---|
| Tightening torque of cylinder head mounting bolt (1st step) | 68.6 Nm {7 kgm} | p. 40 |
| Tightening torque of cylinder head mounting bolt (2nd step) | 107.8 Nm {11 kgm} | p. 40 |
| Radial play of rotor (Standard) | 0.394 – 0.602 mm | p. 36 |
| End play of rotor (Standard) | 0.010 – 0.076 mm | p. 36 |
| Clearance of impeller body | 0.3 – 2.0 mm | p. 74 |
| Standard interference between shaft and fan pulley boss | 0.053 – 0.082 mm | p. 74 |
| Injection pump injection interval | 90° ± 30’ | p. 94 |
| Injection pump plunger pre-stroke | 0.45 mm | p. 94 |
| High idling speed | 2,650 ± 50 rpm | p. 24 |
| Low idling speed | 800 rpm | p. 24 |
| Lubricating oil amount (refill capacity) | 12 L | p. 24 |
| Coolant amount (Engine side) | 4.5 L | p. 24 |
