Returning a Komatsu SAA4D95LE-5-A diesel engine to factory tolerance is what the 320 pages of this shop manual PDF (OEM ID 4D95LE-BE3) are for, and it lists the engine against twelve FD series designations, including FD35-10 through FD80-10. Troubleshooting takes up the largest part of the book. It pairs a failure code table with E-mode electrical charts and S-mode mechanical charts that trace a symptom back to its cause. Wiring diagrams show the starting, charging and engine controller circuits, and the common rail fuel system is broken down from the supply pump through to the injectors, sensors and connectors. Hold main journal clearance to 0.043 to 0.103 mm and crankshaft end play to 0.131 to 0.351 mm. At the stand, there's nobody else to ask. The PDF is bookmarked and text-searchable, so it goes with you to the bench, the shop or a laptop, and every clearance and torque value is there before your engine goes back together.
What's Inside This Manual
| System | Pages | Key Topics |
|---|
| Index and Foreword | 1-46 | General Precautions, Preparations for Work, Precautions for Sling Work |
| Specification | 47-60 | Outline, Specifications, Weight Table, Engine Performance Curves |
| Structure, Function and Maintenance Standard | 61-130 | Air Intake and Exhaust System (Turbocharger) |
| Standard Value Table | 131-136 | Standard Service Value Table, Running-In Standard |
| Testing and Adjusting | 137-160 | Testing and Adjusting Tools List, Testing Exhaust Temperature, Valve Clearance, Testing Compression Pressure, Testing Blow-By Pressure, Testing Oil Pressure |
| Troubleshooting | 161-280 | General Information on Troubleshooting, Failure Code Table, Troubleshooting for Mechanical System, Troubleshooting for Electrical System |
| Disassembly and Assembly | 281-320 | How to Read This Manual, Coating Materials List, Special Tools List, Disassembly and Assembly Procedure for Fuel Supply Pump Unit |
Quick Reference Specifications
| Specification | Value | Page |
|---|
| Holder mounting bolt | 27 – 30 Nm {2.8 – 3.1 kgm} | p. 142 |
| End play | 0.131 – 0.351 mm | p. 80 |
| Clearance of main journal | 0.043 – 0.103 mm | p. 80 |
| Clearance between camshaft and bushing | 0.040 – 0.140 mm | p. 81 |
| Clearance between connecting rod bushing and piston pin | 0.020 – 0.039 mm | p. 83 |
| Air bleeding plug (fuel main filter) torque | 7.8 – 9.8 Nm {0.8 – 1.0 kgm} | p. 153 |
| Intake valve clearance | 0.35 mm | p. 132 |
| Exhaust valve clearance | 0.50 mm | p. 132 |
| Oil temperature | 90 – 110 °C | p. 132 |
| Fan speed | 2,400 ± 60 rpm | p. 132 |
| High-pressure pipe flare nut (Both ends) | 25.5 – 29.4 Nm {2.6 – 3.0 kgm} | p. 143 |
| Engine Rated Output (FD40Z-10, FD35-10, FD40-10, FD45-10, FD50A-10) | 62.5 kW/2,400 rpm | p. 134 |
