Komatsu 114E-6 Series Engine Shop Manual SEN06506-09 – PDF DOWNLOAD

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Komatsu 114E-6 Series Engine Shop Manual SEN06506-09 – PDF DOWNLOAD

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Komatsu 114E-6 Series Engine Shop Manual SEN06506-09 – PDF DOWNLOAD

FOREWORD, SAFETY, BASIC INFORMATION:
HOW TO READ THE ENGINE SHOP MANUAL:
• Some of the attachments and options described in this shop manual may not be available in some areas. If
they are required, consult your Komatsu distributor.
• The materials and specifications are subject to change without notice.
• Shop manuals are available for “machine part” and “engine part”. For the engine unit, see the shop manual
for the machine which has the same engine model.
• Actual machine may differ from the images which are contained in this manual. A typical model is shown in
the illustrations of this shop manual.
Composition of the shop manual:
This shop manual contains technical information necessary to perform services in workshops. It is divided into
the following chapters for the ease of use.
00 INDEX AND FOREWORD
This section describes the index, foreword, safety, and basic information.
01 SPECIFICATIONS
This section describes the specifications of the machine.
10 STRUCTURE AND FUNCTION
This section describes the structure and operation of each component with respect to each system. “STRUCTURE
AND FUNCTION” is helpful in not only understanding the structure of each component but performing
troubleshooting.
20 STANDARD VALUE TABLE
This section describes the standard values for new machine and failure criteria for testing and adjusting, and
troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge
troubles in troubleshooting.
50 DISASSEMBLY AND ASSEMBLY
This section describes the special tools, work procedures, and safety precautions necessary for removal, installation,
disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and
weight of the coating materials, lubricants, and coolant necessary to these works are shown.
60 MAINTENANCE STANDARD
This section describes the maintenance standard value of each component. The maintenance standard shows
the criteria and remedies for disassembly and assembly.

TABLE OF CONTENTS:

Komatsu 114E-6 Series Engine Shop Manual SEN06506-09 – PDF DOWNLOAD

COVER 1
00 INDEX AND FOREWORD 3
INDEX 4
ABBREVIATION LIST 6
FOREWORD, SAFETY, BASIC INFORMATION 12
HOW TO READ THE ENGINE SHOP MANUAL 12
SAFETY NOTICE FOR OPERATION 14
PRECAUTIONS TO PREVENT FIRE 22
ACTIONS IF FIRE OCCURS 24
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 25
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS 26
PRECAUTIONS FOR DEF 27
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING 27
PRECAUTIONS FOR ADDING 27
PRECAUTIONS FOR STORING 27
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE 27
THE OTHER PRECAUTIONS 27
STORE AdBlue/DEF 28
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 29
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS 32
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT 39
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 41
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 42
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 43
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER 43
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER 44
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER 45
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 47
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR 51
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR 52
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL 54
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH 55
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 57
HOW TO READ ELECTRICAL WIRE CODE 58
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 62
STANDARD TIGHTENING TORQUE TABLE 65
CONVERSION TABLE 72
01 SPECIFICATIONS 77
CONTENTS 78
ABBREVIATION LIST 79
SPECIFICATIONS 85
OUTLINE OF EXHAUST GAS REGULATION 85
SYSTEM DRAWINGS OF ENGINE CONFORMED TO TIER4 REGULATION 86
IMPROVED POINTS OF ENGINE CONFORMED TO TIER4 REGULATION 87
LIST OF APPLICABLE MACHINES: 114E-6 88
SPECIFICATIONS 89
SPECIFICATIONS: SAA6D114E-6 (D65EX-18, D65EX-18E0, D65EXI-18, D65EXI-18E0, D65PX-18, D65PX-18E0, D65PXI-18, D65PXI-18E0, D65WX-18, D65WX-18E0) 89
SPECIFICATIONS: SAA6D114E-6 (D71EX-24, D71EX-24E0, D71EXI-24, D71EXI-24E0, D71PX-24, D71PX-24E0, D71PXI-24, D71PXI-24E0) 90
SPECIFICATIONS: SAA6D114E-6 (HB365LC-3) 91
SPECIFICATIONS: SAA6D114E-6 (PC360LC-11, PC360LCI-11) 92
ENGINE GENERAL VIEW 93
ENGINE GENERAL VIEW: SAA6D114E-6 (D65EX-18, D65EX-18E0, D65EXI-18, D65EXI-18E0, D65PX-18, D65PX-18E0, D65PXI-18, D65PXI-18E0, D65WX-18, D65WX-18E0) 93
ENGINE GENERAL VIEW: SAA6D114E-6 (D71EX-24, D71EX-24E0, D71EXI-24, D71EXI-24E0, D71PX-24, D71PX-24E0, D71PXI-24, D71PXI-24E0) 97
ENGINE GENERAL VIEW: SAA6D114E-6 (HB365LC-3) 101
ENGINE GENERAL VIEW: SAA6D114E-6 (PC360LC-11, PC360LCI-11) 105
ENGINE PERFORMANCE CURVE 109
ENGINE PERFORMANCE CURVE: SAA6D114E-6 (D65EX-18, D65EX-18E0, D65EXI-18, D65EXI-18E0, D65PX-18, D65PX-18E0, D65PXI-18, D65PXI-18E0, D65WX-18, D65WX-18E0) 109
ENGINE PERFORMANCE CURVE: SAA6D114E-6 (D71EX-24, D71EX-24E0, D71EXI-24, D71EXI-24E0, D71PX-24, D71PX-24E0, D71PXI-24, D71PXI-24E0) 110
ENGINE PERFORMANCE CURVE: SAA6D114E-6 (HB365LC-3, PC360LC-11, PC360LCI-11) 111
10 STRUCTURE AND FUNCTION 113
CONTENTS 114
ABBREVIATION LIST 116
UREA SCR SYSTEM 122
LAYOUT DRAWING OF UREA SCR SYSTEM 122
UREA SCR SYSTEM DIAGRAM 124
FUNCTION OF UREA SCR SYSTEM 126
FUNCTION OF AdBlue/DEF SUPPLY SYSTEM 126
INDUCEMENT STRATEGY 129
COMPONENT PARTS OF UREA SCR SYSTEM 143
AdBlue/DEF MIXING TUBE 143
SCR ASSEMBLY 144
AdBlue/DEF TANK 146
AdBlue/DEF PUMP 148
AdBlue/DEF INJECTOR 149
AdBlue/DEF HOSE 150
AdBlue/DEF TANK HEATING VALVE 151
ENGINE SYSTEM 152
LAYOUT OF ENGINE COMPONENTS 152
LAYOUT DRAWING OF ENGINE COMPONENTS 152
INTAKE AND EXHAUST SYSTEM PARTS 154
LAYOUT DRAWING OF INTAKE AND EXHAUST SYSTEM 154
INTAKE AND EXHAUST SYSTEM CIRCUIT DIAGRAM 155
FUNCTION OF INTAKE AND EXHAUST SYSTEM 155
AIR CLEANER 157
INTAKE AIR HEATER 159
ENGINE MAIN BODY PARTS 160
CYLINDER HEAD 160
CYLINDER BLOCK 162
MAIN MOVING PARTS 164
VIBRATION DAMPER 167
TIMING GEAR 168
FRONT COVER 169
VALVE SYSTEM 170
FLYWHEEL AND FLYWHEEL HOUSING 171
TURBOCHARGER SYSTEM 172
CIRCUIT DIAGRAM OF VGT SYSTEM 172
FUNCTION OF VGT SYSTEM 173
VGT 174
EGR SYSTEM 178
EGR VALVE 180
EGR COOLER 182
KCCV SYSTEM 184
KCCV VENTILATOR 188
KDPF 190
LUBRICATION SYSTEM 194
LAYOUT DRAWING OF LUBRICATION SYSTEM PARTS 194
LUBRICATION SYSTEM CIRCUIT DIAGRAM 195
ENGINE OIL PUMP 196
ENGINE BOOST OIL PUMP 197
ENGINE OIL FILTER 198
ENGINE OIL COOLER 199
SAFETY VALVE OF ENGINE OIL FILTER 200
ENGINE OIL PAN 201
FUEL SYSTEM 202
LAYOUT DRAWING OF FUEL SYSTEM PARTS 202
FUEL SYSTEM CIRCUIT DIAGRAM 203
FUNCTION OF FUEL SYSTEM 203
SUPPLY PUMP 206
FUEL PREFILTER 209
FUEL MAIN FILTER 210
COOLING SYSTEM 211
LAYOUT DRAWING OF COOLING SYSTEM PARTS 211
COOLING SYSTEM CIRCUIT DIAGRAM 212
DRIVE PULLEY 214
WATER PUMP 216
THERMOSTAT 217
ELECTRICAL SYSTEM 219
COMPONENT PARTS OF ELECTRICAL SYSTEM 219
ALTERNATOR 219
STARTING MOTOR 222
ENGINE WIRING HARNESS 225
ENGINE CONTROLLER 227
SENSOR 234
LAYOUT DRAWING OF ENGINE SENSOR 234
STRUCTURE OF AMBIENT PRESSURE SENSOR 237
FUNCTION OF AMBIENT PRESSURE SENSOR 237
STRUCTURE OF ENGINE OIL PRESSURE SWITCH 238
FUNCTION OF ENGINE OIL PRESSURE SWITCH 238
STRUCTURE OF CHARGE (BOOST) PRESSURE AND TEMPERATURE SENSOR 239
FUNCTION OF CHARGE (BOOST) PRESSURE AND TEMPERATURE SENSOR 239
STRUCTURE OF COOLANT TEMPERATURE SENSOR 240
FUNCTION OF COOLANT TEMPERATURE SENSOR 240
STRUCTURE OF NE (CRANKSHAFT) SPEED SENSOR 241
FUNCTION OF NE (CRANKSHAFT) SPEED SENSOR 241
STRUCTURE OF Bkup (CAMSHAFT) SPEED SENSOR 242
FUNCTION OF Bkup (CAMSHAFT) SPEED SENSOR 242
STRUCTURE OF COMMON RAIL PRESSURE SENSOR 243
FUNCTION OF COMMON RAIL PRESSURE SENSOR 243
STRUCTURE OF EGR VALVE LIFT SENSOR 244
FUNCTION OF EGR VALVE LIFT SENSOR 244
STRUCTURE OF VGT SPEED SENSOR 245
FUNCTION OF VGT SPEED SENSOR 245
STRUCTURE OF VGT POSITION SENSOR 246
FUNCTION OF VGT POSITION SENSOR 246
STRUCTURE OF MASS AIR FLOW AND TEMPERATURE SENSOR 247
FUNCTION OF MASS AIR FLOW AND TEMPERATURE SENSOR 247
STRUCTURE OF KDPF DIFFERENTIAL PRESSURE AND OUTLET PRESSURE SENSOR 248
FUNCTION OF KDPF DIFFERENTIAL PRESSURE AND OUTLET PRESSURE SENSOR 248
STRUCTURE OF CRANKCASE PRESSURE SENSOR 249
FUNCTION OF CRANKCASE PRESSURE SENSOR 249
STRUCTURE OF AIR CLEANER CLOGGING SENSOR 250
FUNCTION OF AIR CLEANER CLOGGING SENSOR 250
STRUCTURE OF WATER-IN-FUEL SENSOR 251
FUNCTION OF WATER-IN-FUEL SENSOR 251
20 STANDARD VALUE TABLE 253
CONTENTS 254
ABBREVIATION LIST 255
STANDARD VALUE TABLE FOR ENGINE 261
STANDARD VALUE TABLE FOR ENGINE: SAA6D114E-6 (D65EX-18, D65EX-18E0, D65EXI-18, D65EXI-18E0, D65PX-18, D65PX-18E0, D65PXI-18, D65PXI-18E0, D65WX-18, D65WX-18E0) 261
STANDARD VALUE TABLE FOR ENGINE: SAA6D114E-6 (D71EX-24, D71EX-24E0, D71EXI-24, D71EXI-24E0, D71PX-24, D71PX-24E0, D71PXI-24, D71PXI-24E0) 265
STANDARD VALUE TABLE FOR ENGINE: SAA6D114E-6 (HB365LC-3) 269
STANDARD VALUE TABLE FOR ENGINE: SAA6D114E-6 (PC360LC-11, PC360LCI-11) 273
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD 277
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA6D114E-6 (D65EX-18, D65EXI-18, D65PX-18, D65PXI-18, D65WX-18) 277
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA6D114E-6 (D65EX-18E0, D65EXI-18E0, D65PX-18E0, D65PXI-18E0, D65WX-18E0) 279
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA6D114E-6 (D71EX-24, D71EX-24E0, D71EXI-24, D71EXI-24E0, D71PX-24, D71PX-24E0, D71PXI-24, D71PXI-24E0) 281
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA6D114E-6 (HB365LC-3) 283
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA6D114E-6 (PC360LC-11, PC360LCI-11) 285
50 DISASSEMBLY AND ASSEMBLY 287
CONTENTS 288
ABBREVIATION LIST 289
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY 295
HOW TO READ THIS MANUAL 295
COATING MATERIALS LIST 297
SPECIAL TOOLS LIST 301
SKETCHES OF SPECIAL TOOLS 303
ENGINE SYSTEM 304
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY 304
METHOD FOR DISASEMBLING ENGINE GENERALLY 305
METHOD FOR ASEMBLING ENGINE GENERALLY 336
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY 388
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY 388
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY 390
REMOVE AND INSTALL ENGINE FRONT OIL SEAL 394
METHOD FOR REMOVING ENGINE FRONT OIL SEAL 394
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL 395
REMOVE AND INSTALL ENGINE REAR OIL SEAL 398
METHOD FOR REMOVING ENGINE REAR OIL SEAL 398
METHOD FOR INSTALLING ENGINE REAR OIL SEAL 399
60 MAINTENANCE STANDARD 407
CONTENTS 408
ABBREVIATION LIST 409
ENGINE SYSTEM 415
INTAKE AND EXHAUST SYSTEM PARTS 415
MAINTENANCE STANDARD OF VGT 415
ENGINE MAIN BODY PARTS 416
MAINTENANCE STANDARD OF CYLINDER HEAD 416
MAINTENANCE STANDARD OF CYLINDER BLOCK 418
MAINTENANCE STANDARD OF CYLINDER LINER 420
MAINTENANCE STANDARD OF CRANKSHAFT 422
MAINTENANCE STANDARD OF PISTON 424
MAINTENANCE STANDARD OF CONROD 425
MAINTENANCE STANDARD OF VIBRATION DAMPER 427
MAINTENANCE STANDARD OF TIMING GEAR 428
MAINTENANCE STANDARD OF CAMSHAFT 429
MAINTENANCE STANDARD OF VALVE AND VALVE GUIDE 430
MAINTENANCE STANDARD OF ROCKER ARM 432
MAINTENANCE STANDARD OF FLYWHEEL 433
LUBRICATION SYSTEM 435
MAINTENANCE STANDARD OF ENGINE OIL PUMP 435
INDEX 437

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