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 |
Komatsu S4D95LE-3 Engine (CX50 Series) Common Problems This Manual Covers
Komatsu S4D95LE-3 starts then stalls within seconds, hunting at low idle before dying
Bleed air from the fuel system and check the fuel filter for restriction. Verify low idle holds at 800 rpm against the specs on page 24, then work the troubleshooting procedures starting on page 103. If it still hunts, pop test the injectors; opening pressure below the 20.1 to 21.1 MPa spec on page 122 means worn nozzles.
Manual Section: Troubleshooting p. 103Coolant temperature climbs into the red at full load, overflow bottle spits coolant
Check coolant level first; the engine side holds 4.5 L. Inspect the radiator core for restriction and test the thermostat in hot water. Pull the water pump and measure impeller body clearance; the maintenance standard on page 74 calls for 0.3 to 2.0 mm. Replace the pump if the impeller wobbles on the shaft or the seal weeps.
Manual Section: Structure, Function and Maintenance Standard p. 74Hard starting when cold, cranks strong but fires late with white smoke
Adjust valve clearance to 0.35 mm intake and 0.50 mm exhaust on a cold engine, then torque the lock nuts to 44.0 Nm per page 148. Check fuel injection timing next; the spec on page 122 is 5 degrees plus or minus 0.75. Bleed the fuel lines and test compression before blaming the injection pump.
Manual Section: S-1 Starting performance is poor p. 103Oil pressure lamp flickers at hot idle, pressure recovers when engine speed rises
Check the oil level and grade first; refill capacity is 12 L per the specs on page 24. Verify the sender and gauge with a mechanical test gauge before condemning the oil pump. If pressure is truly low, drop the pan and inspect main and rod bearings; torque connecting rod cap bolts to 39.0 Nm on the first step, per page 140.
Manual Section: S-12 Oil pressure caution lamp lights upBlue exhaust smoke under load with oil consumption climbing steadily between service intervals
Inspect the turbocharger for oil carryover past the seals; check rotor shaft play against the maintenance standards starting on page 31 before condemning the rings. If the turbo checks clean, run a compression test and plan on valve guide and ring work covered from page 153. Torque turbocharger mounting nuts to 22.5 to 29.4 Nm on reassembly, per page 152.
Manual Section: S-8 Oil consumption is excessive or exhaust smoke is blueFrequently Asked Questions
What are the torque specifications for the cylinder head mounting bolts on the Komatsu S4D95LE-3 engine?
The cylinder head mounting bolts must be tightened in three steps. The first step is 69 ± 9.8 Nm (7.0 ± 1.0 kgm), the second step is 168.0 ± 4.9 Nm (11.0 ± 0.5 kgm), and the third step requires marking the bolt head and cylinder head, then turning the bolt 90° +30°/0° to tighten. p. 147
How do I troubleshoot a Komatsu S4D95LE-3 engine that has low power or lacks output?
To troubleshoot low power, refer to the 'S-6 Engine lacks output (no power)' chart on page 110. This chart lists potential causes such as a clogged air cleaner element, seized turbocharger, worn piston rings, or improper fuel injection timing, and provides a systematic method to confirm these causes through questions, check items, and troubleshooting steps. p. 110
What is the standard valve clearance for the intake and exhaust valves on the S4D95LE-3 engine?
The standard valve clearance for both intake and exhaust valves, whether the engine is warm or cold, is 0.35 mm for the intake valve and 0.50 mm for the exhaust valve. p. 148
What is the engine oil capacity for the S4D95LE-3 engine during an oil change?
The engine oil pan capacity for the S4D95LE-3 engine is approximately 11 liters of SAE15W-40 DH1 oil. p. 152
What is the correct fan belt tension for the S4D95LE-3 engine?
The fan belt should deflect 7 to 10 mm when pressed with a finger pressure of 58.8 N (approximately 6 kg) at a point midway between the crankshaft pulley and the alternator. p. 151
Is this Komatsu S4D95LE-3 manual a PDF I download?
You download the Service Manual yourself: 166 pages, searchable PDF, available immediately. Keep a copy on every device you use.
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Print away. There is no DRM and no page limit. Many buyers print one chapter at a time and leave the rest on a tablet.
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