Sen06506-08 114e-6 Series Engines

SEN06506-08
ENGINE 114E -6 SERIES

00 INDEX AND FOREWORD
114E-6 SERIES 00-1

INDEX 00 INDEX AND FOREWORD
INDEX
00 INDEX AND FOREWORD ........................................................................................................................ 00-1
ABBREVIATION LIST ............................................................................................................................. 00-4
FOREWORD, SAFETY, BASIC INFORMATION ................................................................................... 00-10
HOW TO READ THE ENGINE SHOP MANUAL ............................................................................ 00-10
SAFETY NOTICE FOR OPERATION............................................................................................. 00-12
PRECAUTIONS TO PREVENT FIRE............................................................................................. 00-20
ACTIONS IF FIRE OCCURS ......................................................................................................... 00-22
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS ........................................................ 00-23
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS...................................................... 00-24
PRECAUTIONS FOR DEF............................................................................................................. 00-25
STORE AdBlue/DEF ...................................................................................................................... 00-26
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT ...................................................... 00-27
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS................................ 00-30
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT..................................................... 00-37
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT .................................................. 00-39
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT .............................................. 00-40
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER ................................................... 00-41
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS ..................... 00-45
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR ..................... 00-49
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR ....... 00-50
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL ... 00-52
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH .. 00-53
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE .
................................................................................................................................................... 00-55
HOW TO READ ELECTRICAL WIRE CODE ................................................................................. 00-56
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD.................................................... 00-60
STANDARD TIGHTENING TORQUE TABLE................................................................................. 00-63
CONVERSION TABLE ................................................................................................................... 00-70
01 SPECIFICATIONS .................................................................................................................................... 01-1
CONTENTS ............................................................................................................................................ 01-2
SPECIFICATIONS .................................................................................................................................. 01-9
OUTLINE OF EXHAUST GAS REGULATION.................................................................................. 01-9
LIST OF APPLICABLE MACHINES: 114E-6 .................................................................................. 01-12
SPECIFICATIONS ......................................................................................................................... 01-13
ENGINE GENERAL VIEW ............................................................................................................. 01-16
ENGINE PERFORMANCE CURVE ............................................................................................... 01-28
10 STRUCTURE AND FUNCTION ................................................................................................................ 10-1
CONTENTS ............................................................................................................................................ 10-2
UREA SCR SYSTEM............................................................................................................................ 10-10
LAYOUT DRAWING OF UREA SCR SYSTEM .............................................................................. 10-10
UREA SCR SYSTEM DIAGRAM ................................................................................................... 10-12
FUNCTION OF UREA SCR SYSTEM............................................................................................ 10-14
COMPONENT PARTS OF UREA SCR SYSTEM........................................................................... 10-31
ENGINE SYSTEM ................................................................................................................................ 10-40
LAYOUT OF ENGINE COMPONENTS .......................................................................................... 10-40
INTAKE AND EXHAUST SYSTEM PARTS .................................................................................... 10-42
ENGINE MAIN BODY PARTS........................................................................................................ 10-47
TURBOCHARGER SYSTEM ......................................................................................................... 10-59
LUBRICATION SYSTEM................................................................................................................ 10-81
FUEL SYSTEM .............................................................................................................................. 10-89
COOLING SYSTEM....................................................................................................................... 10-98
ELECTRICAL SYSTEM .......................................................................................................................10-105
COMPONENT PARTS OF ELECTRICAL SYSTEM ......................................................................10-105
SENSOR.......................................................................................................................................10-120
00-2 114E-6 SERIES

00 INDEX AND FOREWORD INDEX
20 STANDARD VALUE TABLE ...................................................................................................................... 20-1

CONTENTS ............................................................................................................................................ 20-2
STANDARD VALUE TABLE FOR ENGINE ............................................................................................. 20-9
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) ........
..................................................................................................................................................... 20-9
STANDARD VALUE TABLE FOR ENGINE: SAA6D114E-6 (HB365LC-3)...................................... 20-13
STANDARD VALUE TABLE FOR ENGINE: SAA6D114E-6 (PC360LC-11, PC360LCI-11) ............. 20-17
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD ................................................. 20-21
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA6D114E-6 (D65EX-18,
D65EXI-18, D65PX-18, D65PXI-18, D65WX-18) ........................................................................ 20-21
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA6D114E-6 (D65EX-18E0,
D65EXI-18E0, D65PX-18E0, D65PXI-18E0, D65WX-18E0)....................................................... 20-23
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA6D114E-6 (HB365LC-3)......
................................................................................................................................................... 20-25
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA6D114E-6 (PC360LC-11,
PC360LCI-11)............................................................................................................................. 20-26
50 DISASSEMBLY AND ASSEMBLY............................................................................................................. 50-1
CONTENTS ............................................................................................................................................ 50-2
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY .......................................................... 50-9
HOW TO READ THIS MANUAL....................................................................................................... 50-9
COATING MATERIALS LIST...........................................................................................................50-11
SPECIAL TOOLS LIST .................................................................................................................. 50-15
SKETCHES OF SPECIAL TOOLS................................................................................................. 50-17
ENGINE SYSTEM ................................................................................................................................ 50-18
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY............................................................. 50-18
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY .................................................................50-102
REMOVE AND INSTALL ENGINE FRONT OIL SEAL ..................................................................50-108
REMOVE AND INSTALL ENGINE REAR OIL SEAL.....................................................................50-112
60 MAINTENANCE STANDARD.................................................................................................................... 60-1
CONTENTS ............................................................................................................................................ 60-2
ENGINE SYSTEM .................................................................................................................................. 60-9
INTAKE AND EXHAUST SYSTEM PARTS ...................................................................................... 60-9
ENGINE MAIN BODY PARTS........................................................................................................ 60-10
LUBRICATION SYSTEM................................................................................................................ 60-29
INDEX..................................................................................................................................................................1
114E-6 SERIES 00-3

ABBREVIATION LIST 00 INDEX AND FOREWORD
ABBREVIATION LIST
• This list of abbreviations includes the abbreviations used in the text of the shop manual for parts, compo-
nents, and functions whose meaning is not immediately clear. The spelling is given in full with an outline of
the meaning.
• Abbreviations that are used in general society may not be included.
• Special abbreviations which appear infrequently are noted in the text.
• This list of abbreviations consists of two parts. The first part is a list of the abbreviations used in the text of
the manual, and the second part is a list of the abbreviations used in the circuit diagrams.
List of abbreviations used in the text
Purpose of use (major ap-
Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
Travel and brake This is a function that releases the brake when
ABS Antilock Brake System the tires skid (tires are not rotated). This function
(HD, HM) applies the brake again when the tires rotate.
Automatic Idling Setting This is a function that automatically sets the idle
AISS Engine
System speed.
Steering This is a function that performs the steering oper-
Advanced Joystick ations with a lever instead of using a steering
AJSS
Steering System (WA) wheel. This function performs gear shifting and
changing forward and reverse direction.
Travel and brake This is a function that automatically operates the
Automatic Retarder Ac-
ARAC retarder with a constant braking force when let-
celerator Control (HD, HM) ting go of the accelerator pedal on the downhill.
retarder to ensure that the machine speed does
Automatic Retarder
ARSC not accelerate above the speed set by the opera-
Speed Control (HD, HM) tor when letting go of the accelerator pedal on
the downhill.
Travel and brake This is a function that drives both wheels auto-
Automatic Spin Regula- matically using the optimum braking force when
ASR
tor (HD, HM) the tire on one side spins on the soft ground sur-
faces.
A function or component that can be added to the
ATT Attachment Work equipment
standard specification.
BRAKE This is a valve that bypasses a part of the brake
Brake cooling oil control cooling oil to reduce the load applied to the hy-
BCV
valve (HD) draulic pump when the retarder is not being
used.
Communication and elec- This is one of communication standards that are
CAN Controller Area Network
tronic control used in the network on the machine.
This is a regulator valve that is installed to KCCV
Crankcase Depression
CDR Engine ventilator. It is written as CDR valve and is not
Regulator
used independently.
This is a system that can actuate multiple actua-
Closed-center Load
CLSS Hydraulic system tors simultaneously regardless of the load (pro-
Sensing System
vides better combined operation than OLSS).
00-4 114E-6 SERIES

00 INDEX AND FOREWORD ABBREVIATION LIST

Abbrevia-
tion
component/system)
This is a function that maintains optimum fuel in-
jection amount and fuel injection timing. This is
CRI Common Rail Injection Engine performed the engine controller which electroni-
cally controls supply pump, common rail, and in-
jector.
This is an electronic control device that send the
Electronic Control Mod- command to actuators using the signals from the
ECM Electronic control system
ule sensors on the machine so that the optimum ac-
tuation is performed. (Same as ECU)
Transmission This is a proportional electromagnetic valve that
Electronic Control Mod-
ECMV decreases the transmission shock by gradually
ulation Valve (D, HD, WA, etc) increasing oil pressure for engaging clutch.
Travel This is a device that ensures smooth high-speed
Electronically Controlled
ECSS travel by absorbing vibration of machine during
Suspension System (WA) travel with hydraulic spring effect of accumulator.
command to actuators using the signals from the
ECU Electronic Control Unit Electronic control system
sensors on the machine so that the optimum ac-
tuation is performed. (Same as ECM)
This is a function that recirculates a part of ex-
Exhaust Gas Recircula- haust gas to combustion chamber, so that it re-
EGR Engine
tion duces combustion temperature, and reduces
emission of NOx.
This is a function with which operator can check
Equipment Manage- information from each sensor on the machine (fil-
EMMS Machine monitor
ment Monitoring System ter, oil replacement interval, malfunctions on ma-
chine, failure code, and failure history).
Electromagnetic proportional control This is a
Electromagnetic Propor-
EPC Hydraulic system mechanism with which actuators operate in pro-
tional Control
portion to the current.
This structure protects the operator's head from
Falling Object Protective falling objects. (Falling object protective struc-
FOPS Cab and canopy ture)
Structure
This performance is standardized as ISO 3449.
Forward-Neutral-Re-
F-N-R Operation Forward - Neutral - Reverse
verse
Communication
Global Positioning Sys- This system uses satellites to determine the cur-
GPS (KOMTRAX, KOMTRAX
tem rent location on the earth.
Plus)
Communication
Global Navigation Satel- This is a general term for system uses satellites
GNSS (KOMTRAX, KOMTRAX
lite System such as GPS, GALILEO, etc.
Plus)
Steering This is a function that enables the machine to
Hydrostatic Steering turn without steering clutch by controlling a differ-
HSS
System (D Series) ence in travel speed of right and left tracks with a
combination of hydraulic motor and bevel shaft.
Transmission Hydraulic transmission system that uses a com-
Hydro Static Transmis-
HST bination of hydraulic pump and hydraulic motor
sion (D, WA) without using gears for stepless gear shifting.
114E-6 SERIES 00-5


Abbrevia-
tion
component/system)
A general term for the engineering and its social-
Information and Com- Communication and elec-
ICT ly applied technology of information processing
munication Technology tronic control
and communication.
This is a valve that adjusts the fuel intake amount
IMA Inlet Metering Actuator Engine at the pump inlet in order to control the supply
pump fuel discharged volume. (Same as IMV)
This is a device to detect the angle (or angular
Inertial Measurement
IMU Engine velocity) and acceleration of the 3 axes that con-
Unit
trol motions.
at the pump inlet in order to control the supply
IMV Inlet Metering Valve Engine
pump combustion discharged volume. (Same as
IMA)
This is a mechanism that burns the blowby gas
Komatsu Closed Crank- again by separating oil from blowby gas and re-
KCCV Engine
case Ventilation turning it to the intake side. It primarily consists of
filters.
Komatsu Catalyzed This is a filter that captures soot in exhaust gas.

KCSF Engine
Soot Filter It is built in to KDPF.
This is a catalyst that is used for purifying ex-
Komatsu Diesel Oxida- haust gas.
KDOC Engine
tion Catalyst It is built in to KDPF or assembled with the muf-
fler.
This is a component that is used to purify the ex-
Komatsu Diesel Particu- haust gas. KDOC (catalyst) and KCSF (filter to
KDPF Engine capture soot) are built-in it.
late Filter
It is installed instead of the conventional muffler.
Travel and brake This is a function that performs braking with the
optimum force and recovers the driving force of
Komatsu Traction Con-
KTCS the wheels by actuating the inter-axle differential
trol System (HM) lock when the wheels runs idle while the machine
travels on the soft ground.
This is an image display equipment such as a
LCD Liquid Crystal Display Machine monitor monitor in which the liquid crystal elements are
assembled.
This is a semiconductor element that emits light
LED Light Emitting Diode Electronic parts
when the voltage is applied in forward direction.
Local Interconnect Net- Communication and elec- This is one of communication standards that are
LIN
work tronic control used in the network on the machine.
This is a function that detects differential pres-
LS Load Sensing Hydraulic system sure of pump, and controls discharged volume
corresponding to load.
Low Voltage Differential Communication and elec- This is one of communication standards that are
LVDS
Signaling tronic control used in the network on the machine.
This indicates engine intake air flow. This is not
used independently but is used as combined with
MAF Mass Air Flow Engine
sensor. Mass air flow sensor can be called as
MAF sensor.
00-6 114E-6 SERIES


Abbrevia-
tion
component/system)
This is a service that allows transmission and re-
Multimedia Messaging
MMS Communication ception of short messages consisting of charac-
Service
ters or voice or images between cell phones.
This is a characteristic of electrical or hydraulic
Electrical system, hydraulic
NC Normally Closed circuits. Circuit is normally closed if it is not actu-
system
ated, and it opens when it is actuated.
NO Normally Open circuits. Circuit is normally open if it is not actuat-
system
ed, and it closes when it is actuated.
This is a hydraulic system that can operate multi-
Open-center Load
OLSS Hydraulic system ple actuators at the same time regardless of the
Sensing System
load.
PC Pressure Compensation Hydraulic system This is a function that corrects the oil pressure.
Steering This is a function that electrically controls the en-
Palm command control gine and transmission in an optimal way with the
PCCS
system (D Series) controller instantly analyzing data from levers,
pedals, and dials.
PCV Pre-stroke Control Valve Engine at the pump inlet in order to control fuel dis-
charged volume of supply pump.
Proportional Pressure This is a system that operates actuators in pro-
PPC Hydraulic system
Control portion to the oil pressure.
Hydraulic system
PPM Piston Pump and Motor Piston type hydraulic pump and motor.
(D, PC, etc)
PTO Power Take Off Power train system Power take-off mechanism
Work equipment This is a function that performs hydraulic control
Power Tilt and power
PTP of the tilt and pitch of the dozer blade of the bull-
Pitch dozer (D Series) dozer.
ROPS is a protective structure that intended to
protect the operator wearing seat belt from suffer-
ing injury which may be caused if the cab is
Roll-Over Protective crushed when the machine rolls over. (Roll-over
ROPS Cab and canopy
Structure protective structure)
This performance is standardized as ISO 3471 or
ISO 12117-2.
This is an exhaust gas purifier using urea water
that converts nitrogen oxides (NOx) into harm-
Selective Catalytic Re- less nitrogen and water by oxidation-reduction re-
SCR Urea SCR system
duction action. It may also be mentioned as exhaust gas
purification catalyst or part of the name of related
devices.
Le Systeme Internation- Abbreviation for "International System of Units" It
SI al d' Unites (Internation- Unit is the universal unit system and "a single unit for
al unit system) a single quantity" is the basic principle applied.
This is an actuator that consists of a solenoid and
SOL Solenoid Electrical system an iron core that is operated by the magnetic
force when the solenoid is energized.
114E-6 SERIES 00-7


Abbrevia-
tion
component/system)
This is a protective structure that intended to pro-
tect the operator wearing seat belt from suffering
Tip-Over Protective injury which may be caused if the cab is crushed
TOPS Cab and canopy when the machine tips over. (Roll-over protective
Structure
structure of hydraulic excavator)
This is a solenoid valve that switches over direc-
TWV 2-Way Valve Hydraulic system
tion of flow.
Variable Geometry Tur- This is a turbocharger on which the cross-section
VGT Engine
bocharger area of the exhaust passage is variable.
This is a function that finely controls the maxi-
Variable Horse Power mum output of the machine so that high work effi-
VHPC Engine control
Control ciency and low fuel consumption rate are both
achieved.
*1: Code for applicable machine model

D: Bulldozer
HD: Dump truck
HM: Articulate dump truck
PC: Hydraulic excavator
WA: Wheel loader
List of abbreviations used in the circuit diagrams
Abbreviation Actual word spelled out
A/C Air Conditioner
A/D Analogue-to-Digital
A/M Air Mix Damper
ACC Accessory
ADD Additional
AUX Auxiliary
BR Battery Relay
CW Clockwise
CCW Counter Clockwise
ECU Electronic Control Unit
ECM Electronic Control Module
ENG Engine
EXGND External Ground
F.G. Frame Ground
GND Ground
IMA Inlet Metering Actuator
NC No Connection
00-8 114E-6 SERIES


S/T
Steering
STRG
SIG Signal
SOL Solenoid
STD Standard
OPT
Option
OP
PRESS Pressure
SPEC Specification
SW Switch
TEMP Temperature
T/C Torque Converter
T/M Transmission
114E-6 SERIES 00-9

HOW TO READ THE ENGINE SHOP MANUAL 00 INDEX AND FOREWORD
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. "STRUC-
TURE 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, instal-
lation, 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.
Symbol
Important safety and quality portions are marked with the following symbols so that shop manual is used effec-
tively.
Symbol Item Remark
This signal indicates an extremely hazardous situation which will result in
Danger
death or serious injury if it is not avoided.
This signal indicates a potentially hazardous situation which will result in
Warning
Caution
injury or property damage around the machine if it is not avoided.
This signal indicates the weight of parts and components, and items which
Weight requires great attention to a selection of wires and working posture for
slinging work.
This signal indicates the tightening torque for portions which requires spe-
Tightening torque
cial care in assembling work.
00-10 114E-6 SERIES

00 INDEX AND FOREWORD HOW TO READ THE ENGINE SHOP MANUAL
Symbol Item Remark

This signal indicates a place to be coated with adhesive, grease, etc. in
Coat
assembling work.
Oil and coolant This signal indicates a place to supply oil, coolant, etc. and the quantity.
Draining This signal indicates a place to drain oil, coolant, etc. and the quantity.
This symbol indicates the works which require special caution for the ma-
Safety
chine safety when assembling.
Signal word
Signal word for notice and remark describes the following.
Symbol Item Remark
If the precaution of this signal word is not observed, the machine damage
NOTICE Notice
or shortening of service life may occur.
REMARK Remark This signal word contains useful information to know.
Unit
International System of Units (SI) is used in this manual. For reference, units that have been used in the past
are given in { }.
114E-6 SERIES 00-11

SAFETY NOTICE FOR OPERATION 00 INDEX AND FOREWORD
SAFETY NOTICE FOR OPERATION

• Appropriate servicing and repair are extremely important to ensure safe operation of the machine. The shop
manuals describe the effective and safe servicing and repair methods recommended by Komatsu. Some of
the servicing and repair methods require the use of special tools designed by Komatsu for special purpos-
es.
• The symbol mark is indicated for such matters that require special precautions. The work indicated with
this warning mark should be performed according to the instructions with special attention. Should a
hazardous situation occurs or be anticipated during such work, be sure to keep safe first and take every
necessary measures.
Safety matters
• Well organized work place
• Correct work clothes
• Observance of work standard
• Enforcement of hand signals
• Prohibition against unlicensed persons operating and handling the machine
• Safety check before starting work
• Wear of dust glasses (for cleaning or grinding work)
• Wear of welding goggles and protectors (for welding work)
• Being in good physical condition, and good preparation
• Always be alert and careful.
General precautions
k If the machine is handled incorrectly, it is dangerous. Read and understand what is described in the
operation and maintenance manual before operation. Read and understand what is described in this
manual before operation.
• Read and understand the meaning of all the safety labels stuck to the machine before performing any
greasing or repairs. For the locations of the safety labels and detailed explanation of precautions, see Oper-
ation and Maintenance Manual.
• Tools and removed parts in the workshop should be well organized. Always keep the tools and parts in their
correct places. Always keep the work area clean and make sure that there is no dust, dirt, oil, or water on
the floor. Smoke only in the designated areas. Never smoke while working.
• Keep all tools in good condition, learn the correct way to use them, and use the proper ones. Check the
tools, machine, forklift truck, service car, etc. thoroughly before starting the work.
• Always wear safety shoes and helmet when performing
any operation. Do not wear loose clothes, or clothes with
buttons missing.
00-12 114E-6 SERIES

00 INDEX AND FOREWORD SAFETY NOTICE FOR OPERATION
• Always wear the protective eyeglasses when hitting parts

with a hammer.
• Always wear the protective eyeglasses when grinding
parts with a grinder, etc.
• When performing any operation with multiple workers, al-
ways agree on the operating procedure before starting. Be
clear in verbal communication, and observe hand signals.
Hang "UNDER REPAIR" warning tag in the operator's
compartment Before starting work. ,&
• Work and operation which require license or qualification
should be performed by qualified workers.
• Welding repairs should be performed by trained and experienced welders. When performing welding work,
always wear welding gloves, apron, welding goggles, cap and other clothes suited for welding work.
• Warm up before starting the work with exercise which increases alertness and the range of motion in order
to prevent injury.
• Avoid prolonged work, and take a rest at times to keep up a good condition. Take a rest at designated safe
area.
Precautions for preparatory work
• Place the machine on a firm and level ground, and apply the parking brake and chock the wheels or tracks
to prevent the machine from moving before adding oil or making any repairs.
• Lower the work equipment (blade, ripper, bucket, etc.) to the ground before starting work. If this is not pos-
sible, insert the lock pin or use blocks to prevent the work equipment from falling. In addition, be sure to
lock all the control levers and hang "UNDER REPAIR" warning tag on them.
• When performing the disassembling or assembling work, support the machine securely with blocks, jacks,
or stands before starting the work.
• Remove all mud and oil from the steps or other places for
going up and down on the machine. Always use the hand-
rails, ladders or steps when for going up and down on the
machine. Never jump on or off the machine. When the
scaffold is not provided, use steps or stepladder to secure
your footing. Do not use handrails, ladders, or steps if they
are damaged or deformed. Repair it or replace it immedi-
ately.
,&
Precautions during work

• For the machine with the battery disconnect switch, check before starting the work that the system operat-
ing lamp is not lit. Then, turn the battery disconnect switch to OFF (○) position.
REMARK
Remove the key after it is turned to OFF (○) position if the battery disconnect switch is a switch key type.
For the machine without the battery disconnect switch, turn the starting switch to OFF position, wait for two
minutes or more before starting the work. Disconnect the battery cable by starting from the negative (-) ter-
minal first.
• For the machine with the quick release battery terminal (-), check before starting the work that the system
operating lamp is not lit. Then, disconnect the quick release battery terminal (-).
REMARK
For the machine without the system operating lamp, turn the starting switch to OFF position, wait for two
minutes or more before starting the work. Disconnect the quick release battery terminal (-).
114E-6 SERIES 00-13

• Release the remaining pressure from the circuit before starting the work of disconnecting and removing of
oil, fuel, water, or air from the circuit. When removing the cap of oil filter, drain plug, or oil pressure plug, it
should be done slowly otherwise the oil spills.
• When removing or installing the checking plug or the piping in the fuel circuit, wait 30 seconds or longer
after the engine is shut down and start the work after the remaining pressure is released from the fuel cir-
cuit.
• The coolant and oil in the circuits are hot when the engine
is shut down. Be careful not to get scalded. Wait for the oil
and coolant to cool before performing any work on the oil
or coolant circuits.
• Before starting work, shut down the engine. When working

on or around a rotating part, in particular, shut down the
engine. When checking the machine without shutting down
the engine (measuring oil pressure, revolving speed, tem-
perature, etc.), take extreme care not to get caught in ro-
tating parts or moving parts.
• When raising a heavy component (heavier than 25 kg),
use a hoist or crane. Before starting work, check that the
slings (wire ropes, webbing slings, chains, and hooks) are
free from damage. Always use slings which have ample
capacity and install them to proper places. Operate the
hoist or crane slowly to prevent the component from hitting
any other part. Do not work with any part still raised by the
hoist or crane.
• When removing a part which is under internal pressure or
under reaction force of a spring, always leave 2 bolts in di-
agonal positions. Loosen those 2 bolts gradually and alter-
nately to release the pressure, and then remove the part.
• When removing components, do not break or damage the
electrical wiring. Damaged wiring may cause a fire.
,&
• When removing piping, do not spill the fuel or oil. If any
fuel or oil drips onto the floor, wipe it off immediately. Fuel
or oil on the floor can cause you to slip and can even cause fires.
• Do not use gasoline to wash parts as a general rule. Do not use gasoline to clean electrical parts, in partic-
ular.
00-14 114E-6 SERIES

• Be sure to assemble all parts again in their original places. Replace any damaged parts and parts which
must not be reused with new parts. When installing hoses and wiring harnesses, be sure that they will not
be damaged by contact with other parts when the machine is operated.
• When installing high pressure hoses and tubes, make sure that they are not twisted. Damaged hoses and
tubes are dangerous, so be extremely careful when installing hoses and tubes for high pressure circuits. In
addition, check that high pressure hoses and tubes are correctly installed.
• When assembling or installing parts, always tighten them to the specified torques. When installing protec-
tive parts such as guards, or parts which vibrate violently or rotate at high speed, check again that they are
installed correctly.
• Never insert your fingers or hand when aligning 2 holes. Be careful not to get your fingers caught in a hole.
• Check that the measuring tools are correctly installed when measuring hydraulic pressure.
• Take care when removing or installing the tracks of track-type machines. Since the track shoe may sepa-
rate suddenly when you remove it, never let anyone stand at either end of the track shoe.
• If the engine is operated for a long time in a closed place
with poor ventilation, it may cause gas poisoning. Open
the windows and doors to ventilate the place well.
,&
Precautions for slinging work and making signals

• Only one appointed worker must make signals and co-workers must communicate with each other fre-
quently. The appointed signaler must make specified signals clearly at a place where he is well seen from
the operator's seat and where he can see the working condition easily. The signaler must always stand in
front of the load and guide the operator safely.
k Never stand under the load.
k Do not move a load over a person.
k Never step on the load.
k Do not prevent the load from swinging or falling down by holding it simply with the hands.
k The sling workers and assistant workers other than the guide must move to a place where they
are not caught between the load and materials or equipment on the ground or hit by the load
even if the crane starts abruptly.
• Check the slings before starting sling work.
• Keep putting on gloves during sling work. (Put on leather gloves, if available.)
• Measure the weight of the load by the eye and check its center of gravity.
• Use proper sling corresponding to the weight of the load and method of slinging. If too thick wire ropes are
used to sling a light load, the load may slip and fall.
• Do not sling a load with 1 wire rope alone. If it is slung so, it may rotate and may slip out of the rope. Install
2 or more wire ropes symmetrically.
k Slinging with one rope may cause turning of the load during hoisting, untwisting of the rope, or
slipping of the rope from its original slinging position on the load, which can result in a danger-
ous accident.
• Hanging angle must be 60 ° or smaller as a rule.
• When slinging a heavy load (25 kg or heavier), the hanging angle of the rope must be narrower than that of
the hook.
114E-6 SERIES 00-15

REMARK
When slinging a load with 2 or more ropes, the force sub-
jected to each rope increases with the hanging angle. The
figure below shows the variation of allowable load in kN
{kg} when slinging is made with 2 ropes, each of which is
allowed to sling up to 9.8 kN {1000 kg} vertically, at vari-
ous hanging angles. When the 2 ropes sling a load verti-
cally, they can sling up to 2000 kg of total weight. This
weight is reduced to 1000 kg when the 2 ropes make a
hanging angle of 120 °. If the 2 ropes sling a 2000 kg load
at a hanging angle of 150 °, each rope is subjected to a
force as large as 39.2 kN {4000 kg} .
• When installing wire ropes to an angular load, apply pads to protect the wire ropes. If the load is slippery,
apply proper material to prevent the wire rope from slipping.
• Use the specified eye bolts and fix wire ropes, chains, etc. to them with shackles, etc.
• Apply wire ropes to the middle part of the hook.
k Do not use hooks if it does not have a latch sys-
tem.
k Slinging near the tip of the hook may cause the
rope to slip off the hook during hoisting.
REMARK
The strength of the hook is maximum at its central part.
• Never use a wire rope which has breaks in strands (A), re-
duced diameter (B), or kinks (C). There is a danger that
the rope may break during the towing operation.
Precautions for slinging up
• Wind in the crane slowly until wire ropes are stretched.
When settling the wire ropes with the hand, do not grasp
them but press them from above. If you grasp them, your
fingers may be caught.
• After the wire ropes are stretched, stop the crane and
check the condition of the slung load, wire ropes, and
pads.
• If the load is unstable or the wire rope or chains are twisted, lower the load and lift it up again.
• Do not lift up the load at an angle.
Precautions for slinging down
• When slinging down a load, stop it temporarily at 30 cm above the floor, and then lower it slowly.
• Check that the load is stable, and then remove the sling.
• Remove kinks and dirt from the wire ropes and chains used for the sling work, and put them in the specified
place.
Precautions for using mobile crane
REMARK
Read Operation and Maintenance Manual of the crane carefully in advance and operate the crane safely.
Precautions for using overhead traveling crane
k When raising a heavy component (heavier than 25 kg), use a hoist or crane.
00-16 114E-6 SERIES

REMARK
Weight of component whose weight is heavier than 25 kg is shown with symbol in "DISASSEMBLY AND
ASSEMBLY".
• Before starting work, check the wire ropes, brake, clutch, controller, rails, over winding prevention device,
ground fault circuit interrupter for electric shock prevention, crane collision prevention device, and energiz-
ing caution lamp, and check the following safety items.
• Observe the signals for sling work.
• Operate the hoist at a safe place.
• Be sure to check the directions of the direction indication plate (north, south, east and west) and the
operating button.
• Do not sling a load at an angle. Do not move the crane while the slung load is swinging.
• Do not raise or lower a load while the crane is moving longitudinally or laterally.
• Do not drag a sling.
• When lifting up a load, stop it just after it becomes off the ground, check the safety, and then lift it up.
• Consider the travel route in advance and lift up a load to a safe height.
• Place the control switch in a position where it is not an obstacle to work and passage.
• After operating the hoist, do not swing the control switch.
• Remember the position of the main switch so that you can turn off the power immediately in an emer-
gency.
• If the hoist stops because of a power failure, turn off the main switch. When turning on a switch after it
is turned off by the ground fault circuit interrupter, check that the devices related to that switch are not
in operating condition.
• If you find an obstacle around the hoist, stop the operation.
• After finishing the work, stop the hoist at the specified position and raise the hook to at least 2 m above
the floor. Do not leave the sling installed to the hook.
Selecting wire ropes
Select adequate ropes depending on the weight of the parts to be hoisted referring to the table below.
REMARK
The allowable load is calculated with one sixth (safety factor 6) of the breaking load of the rope.
Wire rope (JIS G3525 6x37-A type) (Standard Z twist wire ropes without galvanizing)
Nominal diameter of rope ( mm) Allowable load ( kN { t} )
10 8.8 {0.9}
12 12.7 {1.3}
14 17.3 {1.7}
16 22.6 {2.3}
18 28.6 {2.9}
20 35.3 {3.6}
25 55.3 {5.6}
30 79.6 {8.1}
40 141.6 {14.4}
50 221.6 {22.6}
60 318.3 {32.4}
114E-6 SERIES 00-17

Precautions for disconnecting air conditioner piping

NOTICE
When replacing the air conditioner unit, air conditioner compressor, condenser or receiver drier, etc.,
collect the refrigerant (air conditioner gas: R134a) from the air conditioner circuit before disconnecting
the air conditioner hoses.
REMARK
• Ask a qualified person for collecting, adding and filling operations of the refrigerant (air conditioner gas:
R134a).
• Never release the refrigerant (air conditioner gas: R134a) to the atmosphere.
k Put on the protective eyeglasses, gloves and working clothes with long sleeves while you are col-
lecting or filling the refrigerant. Otherwise, when refrigerant gas (R134a) gets in your eyes, you may
lose your sight, and when it touches your skin, you may suffer from frostbite.
• When loosening the nuts fixing air conditioner hoses and tubes, be sure to use 2 wrenches; use one
wrench to fix and use the other one to loosen the nut.
Precautions for air conditioner piping
• When installing the air conditioner piping, be careful so that dirt, dusts and water do not enter the hose.
• Check that the O-rings are fitted to the joints when connecting the air conditioner piping.
• Do not reuse an O-ring because it is deformed and deteriorated if it is used once.
• When removing the O-rings, use a soft tool so that the piping is not damaged.
• Check that the O-ring is not damaged or deteriorated.
• Apply compressor oil for refrigerant (R134a) to O-ring.
REMARK
Do not apply oil to the threaded portion of a bolt, nut or union.
Manufacturer Part name
DENSO ND-OIL8
VALEO THERMAL SYSTEMS ZXL100PG (PAG46 or equivalent)
SANDEN SP-10
When tightening nuts of the air conditioner hoses and tubes, be sure to use 2 wrenches. Use one wrench to fix
and tighten the nut with the other wrench to the specified torque (Use a torque wrench for tightening).
00-18 114E-6 SERIES

REMARK
• The figure shows an example of fitting of O-ring.
• An O-ring is fitted to every joint of the air conditioner piping.
For tightening torques, see THE OTHER INFORMATION, "Pre-
cautions for disconnection and connection of air conditioner
piping".
114E-6 SERIES 00-19

PRECAUTIONS TO PREVENT FIRE 00 INDEX AND FOREWORD
PRECAUTIONS TO PREVENT FIRE

Fire caused by fuel, oil, coolant or window washer fluid
Do not bring any open flame close to fuel, oil, coolant or win-
dow washer fluid. Always observe the following.
• Do not smoke or use any open flame near fuel or other
flammable substances.
• Shut down the engine before adding fuel.
• Do not leave the machine when adding fuel or oil.
• Tighten all the fuel and oil caps securely.
• Be careful not to spill fuel on overheated surfaces or on
,&
parts of the electrical system.
• After adding fuel or oil, wipe up any spilled fuel or oil.
• Put greasy rags and other flammable materials into a safe
container to maintain safety at the workplace.
• When washing parts with oil, use a non-flammable oil. Do
not use diesel oil or gasoline.There is danger that they
may catch fire.
• Do not weld or use a cutting torch to cut any pipes or tubes
that contain flammable liquids.
• Determine well-ventilated areas for storing oil and fuel. ,&
Keep the oil and fuel in the specified place and do not al-
low unauthorized persons to enter.
• When performing grinding or welding work on the machine, move any flammable materials to a safe place
before starting.
Fire caused by accumulation or attachment of flammable material
• Remove any dry leaves, chips, pieces of paper, coal dust, or any other flammable materials accumulated or
attached to or around the engine exhaust manifold, muffler, or battery, or on the undercovers.
• To prevent fires from being caught, remove any flammable materials such as dry leaves, chips, pieces of
paper, coal dust, or any other flammable materials accumulated around the cooling system (radiator, oil
cooler) or on the undercover.
Fire coming from electric wiring
Short circuits in the electrical system can cause fire. Always observe the following.
• Keep all the electric wiring connections clean and securely tightened.
• Check the wiring every day for looseness or damage. Reconnect any loose connectors or refasten wiring
clamps. Repair or replace any damaged wiring.
Fire caused by piping
Check that all the clamps for the hoses and tubes, guards, and cushions are securely fixed in position.
If they are loose, they may vibrate during operation and rub against other parts.There is danger that this may
lead to damage to the hoses and cause high-pressure oil to spurt out, leading to fire and serious personal injury
or death.
Fire around the machine due to highly heated exhaust gas
Some models and specifications may be equipped with KDPF (Komatsu Diesel Particulate Filter).
KDPF is a system for purifying exhaust gas by removing soot in exhaust gas. In the process of purification (re-
generation), the temperature of discharged exhaust gas may be higher than that of conventional models. Do not
bring any flammable materials close to exhaust pipe outlet.
00-20 114E-6 SERIES

00 INDEX AND FOREWORD PRECAUTIONS TO PREVENT FIRE
• When there are thatched houses, dry leaves or pieces of paper near the work site, set the system to disa-
ble the regeneration before starting work to prevent fire hazards due to highly heated exhaust gas caused
by KDPF regeneration.
See the Operation and Maintenance Manual for the setting procedure.
Explosion caused by lighting equipment
• When checking fuel, oil, battery electrolyte, or coolant, always use lighting equipment with anti-explosion
specifications.
• When taking the electrical power for the lighting equipment from the machine, follow the instructions in the
Operation and Maintenance Manual.
114E-6 SERIES 00-21

ACTIONS IF FIRE OCCURS 00 INDEX AND FOREWORD
ACTIONS IF FIRE OCCURS

• Turn the starting switch to OFF position to stop the engine.
• Use the handrails and steps to get off the machine.
• Do not jump off the machine. You may fall and suffer serious injury.
• The fumes generated by a fire contain harmful materials which have a bad influence on your body when
they are inhaled.
Do not breathe the fumes.
• After a fire, there may be harmful compounds left. If they touch your skin they may have a bad influence on
your body.
Be sure to wear rubber gloves when handling the materials left after the fire.
The material of the gloves, which is recommended is polychloroprene (Neoprene) or polyvinyl chloride (in
the lower temperature environment).
When wearing cotton work gloves, wear rubber gloves under them.
00-22 114E-6 SERIES

00 INDEX AND FOREWORD PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS

To prevent pollution, pay full attention to the way to dispose of waste materials.
• Always drain the oil from your machine in containers. Nev-
er drain the oil and coolant directly onto the ground or
dump into the sewage system, rivers, seas, or lakes.
• Obey appropriate laws and regulations when disposing of
harmful objects such as oil, fuel, coolant, solvent, filters,
batteries, and DEF.
Avoid exposure to burning rubber or plastics which produce a toxic gas that is harmful to people.
• When disposing of parts made of rubber or plastics (hoses, cables, and harnesses), always comply with the
local regulations for disposing industrial waste products.
114E-6 SERIES 00-23

ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS 00 INDEX AND FOREWORD
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS

This machine complies with either regulation Tier4 Final (North America) or Stage IV (EU) (until 2018), Stage V
(EU) (after 2019).
This machine is equipped with the following two exhaust gas treatment systems:
• Komatsu Diesel Particulate Filter (hereafter KDPF): A device which captures soot in the exhaust gas to pu-
rify exhaust gas. This process performs the combustion of soot referred to as "regeneration".
• Urea SCR system: A device which decomposes the toxic nitrogen oxides (NOx) mixed in the exhaust gas
into harmless nitrogen and water. Spraying aqueous urea solution into the exhaust gas produces a reaction
between the nitrogen oxides and ammonia generated from the urea solution and decomposes the nitrogen
oxides into nitrogen and water.
Either AdBlue® or DEF may be used as the aqueous urea solution for the SCR system.
AdBlue® is a registered trade-mark of VDA (Verband der Automobilindustrie e.V.: Automobile Association of
Germany).
DEF is the abbreviation for Diesel Exhaust Fluid.
Commercial DEF that is API approved and meets all the requirements defined in ISO 22241-1.
This solution will be represented as DEF throughout this manual.
About DEF
DEF is necessary for the urea SCR system. DEF is a colorless transparent 32.5% aqueous urea solution. Urea
as main constituent is a material which is used for cosmetics, medical and pharmaceutical products, and fertiliz-
er, etc.
If you add any additional additive agents or water to DEF and use it, the devices will not function properly, and
conformance to the exhaust gas regulations will be lost. In addition, it will cause failure of the machine.
• In Europe, use AdBlue®.
• In North America, use DEF (Diesel Exhaust Fluid) which is certified by API (American Petroleum Institute).
The certified DEF has the API DEF Certification Mark shown as follows. Look for the API DEF Certification
Mark when purchasing DEF.
API Diesel Exhaust Fluid Certification Mark is the trade
mark of API (American Petroleum Institute).
00-24 114E-6 SERIES

00 INDEX AND FOREWORD PRECAUTIONS FOR DEF
PRECAUTIONS FOR DEF

GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING
DEF is a colorless transparent 32.5% aqueous urea solution. Urea as main constituent is a material which is
used for cosmetics, medical and pharmaceutical products, and fertilizer, etc. The following situations require im-
mediate action:
• If it gets on your skin, it may cause inflammation. Immediately take the contaminated clothes or shoes off
and wash it off with water. In addition, use a soap to wash it off thoroughly. If your skin becomes irritated or
begins to hurt, immediately consult a doctor for treatment.
• Do not induce vomiting if swallowed. If swallowed, thoroughly rinse mouth with water and consult a doctor
for treatment.
• Avoid contact with the eyes. If there is contact, flush with clean water for several minutes and consult a doc-
tor for treatment.
• Wear protective eyeglasses when exposed to DEF to protect from solution splashing in your eyes. Wear
rubber gloves when you perform work handling DEF to avoid skin contact.
PRECAUTIONS FOR ADDING

Do not put fluid other than DEF into DEF tank. If diesel fuel or gasoline is added into the tank, it can cause a
fire. Some fluids or agents added can create and emit a toxic gas.
When opening the cap of DEF tank of the machine, the ammonia vapor may escape. Keep your face away from
the filler port during opening or refilling.
PRECAUTIONS FOR STORING

If the temperature of AdBlue/DEF becomes high, harmful ammonia gas may be generated. Completely seal up
its container for storage. When opening the container, perform it where there is good ventilation. For storage,
see “STORE AdBlue/DEF”.
Store AdBlue/DEF avoiding direct sunlight. Always use the original container at the time of purchase. Do not
exchange the container of AdBlue/DEF with another one. If AdBlue/DEF is stored in an iron or aluminum con-
tainer, toxic gas may develop and a chemical reaction may corrode the container.
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE

AdBlue/DEF is non-flammable; however, in the case of a fire it may generate an ammonia gas. Act on the base
of “Actions if fire occurs”.
If AdBlue/DEF is spilled, immediately wipe and wash the area with water. If spilled AdBlue/DEF is left unattend-
ed and the area is not wiped and cleaned, toxic gas or corrosive substance may be produced by chemical reac-
tions.
THE OTHER PRECAUTIONS

When disposing of AdBlue/DEF, treat it as an industrial waste. For the waste treating method, refer to “Precau-
tions for disposing of waste materials”. It should be treated in the same way.
Never use an iron or aluminum container when disposing AdBlue/DEF fluid, because toxic gas may develop and
a chemical reaction may corrode the container. Use a container made of resin (PP, PE) or stainless steel when
handling the fluid waste of AdBlue/DEF.
Do not touch any fluid discharged from urea SCR. This fluid becomes acid by the influence of sulphur in the fuel
or built-in oxidation catalyzer. If it gets on your skin, thoroughly wash it off with water.
Never relocate or modify the exhaust gas after-treatment device. The harmful gas may be exhausted and it can
cause serious damage to the environment as well as violation of laws.
114E-6 SERIES 00-25

STORE AdBlue/DEF 00 INDEX AND FOREWORD
STORE AdBlue/DEF
• If the temperature of AdBlue/DEF becomes high, harmful ammonia gas may be generated. Completely seal
up its container for storage. Only open containers in a well-ventilated area.
• Store AdBlue/DEF avoiding direct sunlight. Always use the original container at the time of purchase. Do
not exchange the container of AdBlue/DEF with another one. If AdBlue/DEF is stored in an iron or alumi-
num container, toxic gas may develop and a chemical reaction may corrode the container.
• AdBlue/DEF freezes at –11 °C. The recommended temperature for storage is -5 °C or above.
The relation between the upper limit of storage temperature and the storage period of AdBlue/DEF is
shown in the table.
Temperature of storage area Storage period
Max.10 °C Up to 36 months
*: Do not store AdBlue/DEF in the temperature of 35 °C or above.

Handling AdBlue/DEF in cold weather
• AdBlue/DEF freezes at –11 °C.
AdBlue/DEF may freeze and expand to break the devices and parts in the tank. The parts inside the tank
may be affected. Add AdBlue/DEF to the specified amount for cold weather (below the level of when AdBl-
ue/DEF may freeze).
• In cold weather, keep AdBlue/DEF or the machine installed with AdBlue/DEF in the indoors where the tem-
perature is at –11 °C or higher to prevent AdBlue/DEF in the tank from freezing.
If AdBlue/DEF or the machine installed with AdBlue/DEF cannot be stored in the indoors where the temper-
ature is at –11 °C or higher (if they are left outdoors in cold weather), AdBlue/DEF in the tank may freeze.
Drain AdBlue/DEF to prevent it from freezing.
00-26 114E-6 SERIES

00 INDEX AND FOREWORD PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT

Because of the higher pressure and more precise hydraulic components, the most common cause of a failure is
dust (foreign material) in the hydraulic circuit. The special care must be taken when adding hydraulic oil, or
when disassembling, or assembling the hydraulic components.
Select an appropriate workplace
• In rain or high winds, or in dusty environment, avoid adding hydraulic oil, replacing filters, or repairing the
machine.
Disassembly and maintenance work in the field
k Any component may jump out or oil may spurt out by the remaining pressure in the hydraulic circuit
and it may result in serious personal injury or death when removing and disassembling of the hy-
draulic equipment is performed.
k Release the remaining pressure from the hydraulic circuit always before performing the work.
• In the field, there is a risk of dust entering the component

during disassembling or maintenance work, and perform-
ance check is hardly performed. Replacement of the as-
sembly is recommended.
• Perform disassembling and maintenance work in the dust
proof area.
Sealing of openings (prevention of flowing out of oil)

Plug the openings of the piping and the device which have been removed to prevent foreign material from enter-
ing and oil from flowing out.
NOTICE
Do not expose the openings or stuff it, otherwise foreign material may enter or leaked oil may pollute
the environment.
Do not discard the oil inconsiderately. Ask the customer for disposal or bring it back to dispose it ap-
propriately.
REMARK
Cover the places tightly with caps, tapes, or plastic bags if it is
hard to provide the plugs.
114E-6 SERIES 00-27

PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 00 INDEX AND FOREWORD
Preventing intrusion of foreign materials during refilling

• During refilling with the hydraulic oil, do not let water enter
the electrical components.
• Clean the oil filler port and its around, refilling pump, oil
jug, or etc.
• Refilling by using an oil cleaning device is better method
since it can filtrate the contaminants accumulated in the oil
during storage.
Replacing hydraulic oil while its temperature is high

• The higher the oil temperature is, the softer the oil is, and the smoother the oil runs. Also, the sludges are
easily discharged from the circuit. Perform the replacement while oil temperature is high.
• Old hydraulic oil needs to be drained as much as possible when replacing.
NOTICE
Old hydraulic oil contaminates the new one if it is mixed since it contains contaminants and sludg-
es, and the service life of the hydraulic oil is shortened.
REMARK
Drain the old hydraulic oil not only from the hydraulic tank but also from the filter and drain plug in the cir-
cuit.
Avoid reusing the hydraulic oil and lubricating oil
Avoid reusing the hydraulic oil and lubricating oil which has been drained from the machine.
If reused, any foreign material may enter the hydraulic equipment, and it may cause a failure.
Flushing operation
• Flushing is required to completely dislodge the contami-
nants and sludges, and existing oil containing those inside
the hydraulic circuit after disassembling and assembling,
and when replacing the oil with the new one.
• Normally, flushing is performed twice. Primary flushing is
performed by using the flushing oil (1) and the secondary
flushing is performed by using the specified hydraulic oil.
Cleaning operation
Perform oil cleaning to remove the contaminants and sludges in the hydraulic circuit after repair of the hydraulic
device (pump, or control valve) or during operation of the machine.
00-28 114E-6 SERIES

00 INDEX AND FOREWORD PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT
REMARK
The oil cleaning equipment can remove the ultra fine (approxi-
mately 3 μm) particles that the filter built in the hydraulic equip-
ment cannot remove. So, it is very effective device.
114E-6 SERIES 00-29

PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIP-
INGS 00 INDEX AND FOREWORD
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS

When performing "testing and adjusting" of the machine, "removal and installation" and "disassembly and as-
sembly" of the components, observe the following precautions.
Precautions for removal and disassembling work
• If the cooling water contains coolant, dispose of it correctly as chemicals. Do not drain it to the sewage
rashly.
• After disconnecting the hoses or tubes, plug them to prevent dust from entering.
• When draining oil, prepare a container with sufficient capacity.
• Check the matchmarks which indicate the installing position, and put matchmarks on the places where they
seem necessary before removal of the components to prevent any mistake when assembling.
• To prevent any excessive force from being applied to the wiring, always hold the connectors when discon-
necting the connectors. Do not pull the wires.
• Attach the tags to wires and hoses so that installation is done to the correct installing positions.
• Check the thickness and number of shims when storing shims.
• When hoisting the components, prepare the slings with sufficient strength.
• When using forcing screws to remove any component, tighten the forcing screws uniformly and alternately.
• Before removing any component, clean the surrounding area and cover the component to prevent any for-
eign material from entering after removal.
• To disconnect the face seal type hose from the cylinder
tube, loosen the joint by gripping the two wrenches togeth-
er, one is the wrench (1) on the hose side, and another is
the wrench (2) on the cylinder tube reaction force point as
shown in the following figure. Use the grip strength on-
ly.Check after disconnecting the hose that the joint portion
of the cylinder and the cylinder tube is tightened to the
specified torque. Re-tighten it if the tightening torque is in-
sufficient.
NOTICE
Cylinder tube is rotated due to the load applied to the
reaction force point of the cylinder tube, and it is a
cause of weakening of the tightening torque. It may
lead to oil leakage.
• After disconnecting the piping or removing a pipe joint, install the following plugs.
NOTICE
When disassembling the machine, check the part number by referring to the Parts Book and use the
appropriate parts according to the usage conditions.
REMARK
The part numbers of O-ring shown in the table indicate the temporary part number when disassembling and
transporting the machine.
00-30 114E-6 SERIES

00 INDEX AND FOREWORD INGS
Introduction of parts for the disassembly of the face seal type hoses and tubes
Hose side Pipe joint side

Nominal No. O-ring (3)
Plug (1) Nut (2)
02 07376-70210 02789-00210 02896-11008
03 07376-70315 02789-00315 02896-11009
04 07376-70422 02789-00422 02896-11012
05 07376-70522 02789-00522 02896-11015
06 07376-70628 02789-00628 02896-11018
Introduction of parts for the disconnection of the taper seal type hoses and
tubes
Hose side Pipe joint side

Nominal No.
Plug (1) Nut (2)
02 07376-50210 07222-00210
03 07376-50315 07222-00312
04 07376-50422 07222-00414
05 07376-50522 07222-00515
06 07376-50628 07222-00616
10 07376-51034 07222-01018
12 07376-51234 07222-01219
14 07376-51443 07222-01422
114E-6 SERIES 00-31

Introduction of parts for the disconnection of the split flange type hoses and
tubes
Nomi Bolt pitch (mm) Hose side Tube side

nal Split flange Sleeve head O-ring (4) Bolt (5) Washer (6)
No. a b Flange (1)
(2) (3)
04 38.1 17.5 07379-00400 07371-30400 07378-10400 07000-12021 01010-80825 01643-50823
05 42.9 19.8 07379-00500 07371-30500 07378-10500 07000-13022 01010-80830 01643-50823
06 47.6 22.2 07379-00640 07371-30640 07378-10600 07000-13025 07372-51035 01643-51032
10 52.4 26.2 07379-01044 07371-31049 07378-11000 07000-13032 07372-51035 01643-51032
58.7 30.2 07379-01250 07371-31255 07378-11200 07000-13038 07372-51035 01643-51032
12
66.7 31.8 07379-01260 07371-51260 07378-11210 07000-13038 01010-81245 01643-51232
69.9 35.8 07379-01460 07371-31465 07378-11400 07000-13048 07372-51240 01643-51232
14
79.4 36.5 07379-01470 07371-51470 07378-11410 07000-13048 01010-81455 01643-31445
77.8 42.8 07379-02071 07371-32076 07378-12000 07000-12060 07372-51240 01643-51232
20
96.8 44.5 07379-02080 07371-52080 07378-12010 07000-12060 01010-81865 01643-31845
24 88.9 50.8 07379-02484 07371-12484 07378-12400 07000-12070 07372-51240 01643-51232
30 106.4 62 07379-03010 07371-13010 07378-13000 07000-12085 07372-51650 01643-51645
34 120.6 69.8 07379-03411 07371-13411 07378-13400 07000-12100 07372-51650 01643-51645
40 130.2 77.8 07379-04012 07371-14012 07378-14000 07000-12110 07372-51650 01643-51645
50 152.4 92 07379-05011 07371-15011 07378-15000 07000-12135 07372-51655 01643-51645
Introduction of parts for the removal of O-ring boss type joint
00-32 114E-6 SERIES

Nominal No. Plug (1) O-ring (2)

08 07040-10807 07002-10823
10 07040-11007 07002-11023
12 07040-11209 07002-11223
14 07040-11409 07002-11423
16 07040-11612 07002-11623
18 07040-11812 07002-11823
20 07040-12012 07002-12034
24 07040-12412 07002-12434
30 07041-13012 07002-13034
33 07040-13316 07002-13334
36 07041-13612 07002-13634
42 07040-14220 07002-14234
52 07040-15223 07002-15234
Introduction of parts for the removal of taper pipe thread type joint
Nominal Plug (1)

Nominal No.
thread size Square head type (A) Hexagonal socket head (B)
01 R1/8 07042-00108 07043-00108
02 R1/4 07042-00211 07043-00211
03 R3/8 07042-00312 07043-00312
04 R1/2 07042-00415 07043-00415
06 R3/4 07042-00617 07043-00617

10 R1 07042-01019 07043-01019
12 R11/4 07042-01222 07043-01222
14 R11/2 07042-01422 07043-01422

20 R2 07042-02026 07043-02026
Precautions for installation and assembling work

• Tighten the bolts and nuts (sleeve nuts) to the specified torque (KES) unless otherwise specified.
• Install the hoses without twist and interference. If there is any in-between clamp, securely fasten it.
114E-6 SERIES 00-33

• Replace all of the gaskets, O-rings, cotter pins, and lock plates with new ones.
• Bend the cotter pins and lock plates securely.
• When applying adhesive, clean and degrease the surface to apply, and apply 2 to 3 drops of adhesive to
the threaded portion.
• When applying liquid gasket, clean and degrease the surface, and apply it uniformly after making sure that
the surface is free from dust or damage.
• Clean all of the parts. If there is any damage, dents, burrs, or rust found on them, repair it.
• Apply engine oil to the rotating parts and sliding surface.
• Apply molybdenum disulfide lubricant (LM-P) to the surfaces of the press-fitting parts.
• After installing the snap ring, check that the snap ring is settled in the ring groove completely.
• When connecting wiring harness connectors, clean the connectors to remove oil, dust, or water, then con-
nect them securely.
• Use the eye bolts without fatigue and deformation and screw them in securely. Match the directions of the
eyes and the hook.
• When installing split flanges, tighten the bolts uniformly and alternately to prevent uneven tightening.
• As a rule, apply liquid gasket (LG-5) or liquid sealant (LS-2) to the threaded portion of each taper male
screws which receive pressure.
REMARK
If the threaded portion is difficult to degrease, you may use a seal tape.
When winding a seal tape onto a right-handed taper male screw, start winding the screw clockwise from the
third thread in the advancing direction of the threads seeing from the screw end.
NOTICE
If the seal tape is wound counterclockwise, it may become loose when screwed in, and it may come
off. If the sealed tip is pushed outside, it may cause oil leakage.
• To connect the face seal type hose to the cylinder tube,
tighten the joint by gripping the two wrenches together,
one is the wrench (1) on the hose side, and another is the
wrench (2) on the cylinder tube reaction force point at the
same time as shown in the following figure. Use the grip
strength only.Check after connecting the hose that the joint
portion of the cylinder and the cylinder tube is tightened to
the specified torque. Re-tighten it if the tightening torque is
insufficient.
NOTICE
Cylinder tube is rotated due to the load applied to the
reaction force point of the cylinder tube, and it is a
cause of weakening of the tightening torque. It may
lead to oil leakage.
NOTICE
When assembling the hydraulic equipment such as cylinders, pumps and pipings which are removed,
be sure to bleed air from the hydraulic circuit before operating it for the first time according to the fol-
lowing procedure.
1. Start the engine, and run it at low idle.
2. Perform the operation to extend and retract each cylinder of the work equipment and stop it at approximate-
ly 100 mm before the stroke end for 4 or 5 times.
3. Perform the operation to extend and retract each cylinder of the work equipment and stop it at the stroke
end for 3 or 4times.
00-34 114E-6 SERIES

NOTICE
After repair is finished, when operating the machine which has been stored for a long period, bleed air
from the hydraulic circuit according to the same procedure.
Precautions at the time of completion of work
Refilling of coolant or water or oil, greasing, and adding of AdBlue/DEF
• For machines with urea SCR system, fill AdBlue/DEF to the specified level before starting the engine.
• Supply the specified amount of grease to the work equipment parts.
• When the coolant is drained, be sure that the drain valve is securely tightened, then refill the coolant reser-
voir with the coolant Komatsu recommends to the specified level. Start the engine to circulate the coolant in
the piping, and add the coolant to the specified level again.
• When the hydraulic components are removed and installed, refill the tank with the oil Komatsu recommends
to the specified level. Start the engine to circulate the oil in the piping, and add the oil to the specified level
again.
• If the hydraulic piping or hydraulic equipment is removed, be sure to bleed air from the system after rebuild-
ing the parts, by referring to TESTING AND ADJUSTING.
Testing installed condition of cylinder heads and manifolds
• Check the cylinder head and intake and exhaust manifold mountings for looseness.
• If there is any looseness, retighten the part.
REMARK
For the tightening torques, see "DISASSEMBLY AND ASSEMBLY".
Test engine piping for damage and looseness
Intake and exhaust system
Check that there is no damage on the pipings, or no looseness on mounting bolts, nuts and clamps, or no leak
of air or exhaust gas from connecting portion.
If there is any looseness, damage, or gas leak, retighten or repair the part.
Cooling system
Check that there is no damage on the pipings, no looseness on mounting bolts, nuts and clamps, and no water
leak from connecting portion.
If there is any looseness, damage, or water leak, retighten or repair the part.
Fuel system
Check that there is no damage on the pipings, no looseness on mounting bolts, nuts and clamps, and no fuel
leak from connecting portion.
If there is any looseness, damage, or fuel leak, retighten or repair the part.
Check the exhaust equipment and its installation portion for looseness and damage.
REMARK
When an equipment is described as an exhaust equipment, it is one of the followings. (The applications or com-
ponents of equipment are different depending on its models or specifications.)
• KDPF
• AdBlue/DEF mixing tube
• SCR assembly
• KDOC muffler
• Muffler
• Exhaust pipe
• Parts which connects the above, or etc.
Visually check that there is no crack or no damage on the exhaust equipment and its installation portion. If there
is any damage, replace the part.
114E-6 SERIES 00-35

Check that there is no looseness on the exhaust equipment and mounting bolts, nuts, and clamps on the instal-
lation portion.
If there is any looseness, retighten the part.
Check of function of muffler in exhaust system
REMARK
When an equipment is described as an muffler in exhaust system, it is one of the followings. (The applications
or components of equipment are different depending on its models or specifications.)
• KDPF
• AdBlue/DEF mixing tube
• SCR assembly
• KDOC muffler
• Muffler
• Exhaust pipe
• Parts which connects the above, or etc.
Check that there is no unusual noise by comparing to it of the time when the machine was new.
If there is any unusual noise, repair KDPF or muffler, referring to "TROUBLESHOOTING" and "DISASSEMBLY
AND ASSEMBLY".
00-36 114E-6 SERIES

00 INDEX AND FOREWORD PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT

To maintain the performance of the machine over a long period, and to prevent failures or troubles before they
occur, correct "operation", "maintenance and inspection" "troubleshooting", and "repairs" must be performed.
This section deals particularly with correct repair procedures for mechatronics components and is aimed at im-
proving the quality of repairs. For this purpose, it describes the working procedures in "Handling of electrical
equipment".
Handling wiring harnesses and connectors
• Wiring harnesses consist of wires connecting one compo-
nent to another component, connectors used for connect-
ing and disconnecting one wire from another wire, and pro-
tectors or tubes used for protecting the wires.
• Compared with other electrical components fitted in boxes
or cases, wiring harnesses are likely to be directly affected
by rain water, heat, or vibration. Furthermore, during in-
spection and repair operations, they are frequently re-
moved and installed again, so they are likely to suffer de-
formation or damage. For this reason, it is necessary to be
extremely careful when handling and maintenance of the
wiring harnesses.
• If AdBlue/DEF is spilled over wiring harness and connectors, it may cause corrosion and defective contact.
Be careful not to spill it over electrical equipment, wiring harness and connectors since AdBlue/DEF is
strongly corrosive to metal.
Main causes of failure in wiring harness
Defective contact of connectors (defective contact between male and female connectors)
Problems with defective contact are likely to occur because the
male connector is not properly inserted into the female connec-
tor,or because one or both of connectors are deformed or the
position is not correctly aligned, or because there is corrosion
or oxidization of the contact surfaces. The corroded or oxidized
contact surfaces may become shiny again (and contact may
become normal) by connecting and disconnecting the connec-
tors approximately 10 times.
Defective crimping or soldering of connectors

The pins of the male and female connectors are attached to
wires by crimping or soldering. If excessive force is applied to
the wire, the jointed portion (1) may become loose, and it may
result in a defective connection or breakage.
114E-6 SERIES 00-37

PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT 00 INDEX AND FOREWORD
Disconnection in wiring
If the wiring harness is pulled to disconnect the connector, or
the components are lifted with a crane while the wiring harness
is still connected, or a heavy object hits the wiring harness, it
may separate the crimping of the connector, or damage the sol-
dering, or break the wiring harness.
Water entering the connector by high-pressure jetting

The connector is designed to make it difficult for water to enter
(drip-proof structure), but if high-pressure water is sprayed di-
rectly on the connector, water may enter the connector, de-
pending on the direction of the water jet.
Do not spray water directly on the connector.
If the connector is waterproof, intruded water is hardly drained.
Once water enters into the connector, water goes through pins
to cause short-circuit. Drying the drenched connector or take
appropriate actions before providing electricity.
Entry of water, dirt, or dust when disconnecting a con-
nector
If any water, mud or dust is stuck to the outside surface of a connector, it can enter inside the connector when
the connector is disconnected. Before disconnecting the connector, wipe off any stuck water or dirt by using a
dry cloth or blow it with compressed air.
Oil, mud, or dust stuck to connector
If any oil or grease is stuck to the connector and an oil film is
formed on the mating surface of the male and female pins, the
oil prevents electricity from passing through resulting in defec-
tive contact. If any oil, grease, dirt or dust is stuck to the con-
nector, wipe it off with a dry cloth or blow it with compressed air,
and wash it with electrical contact restorer.
NOTICE
• When wiping the jointed portion of the connector, do
not apply excessive force or deform the pins.
• If there is oil or water in the compressed air, it causes
the contacts to become dirtier. Use clean air which any
oil and water has been removed from.
00-38 114E-6 SERIES

00 INDEX AND FOREWORD PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT

The machines equipped with common rail fuel injection system (CRI) consists of more precise parts than the
parts used in the conventional fuel injection pump and nozzle. If foreign material enters this system, it may
cause a failure. Use special care to prevent entry of the foreign material when servicing the fuel system.
Avoid the work of adding hydraulic oil, replacing filters, or repairing the machine in rainy or windy weather, or in
dusty environment.
Sealing the opening
Plug the removed pipes and the openings of the removed components with the caps, tapes, plastic bags, etc. to
prevent foreign material from entering.
NOTICE
Do not expose the openings or stuff it, otherwise foreign
material may enter or leaked oil may pollute the environ-
ment.
Do not discard the oil inconsiderately. Ask the customer
for disposal or bring it back to dispose it appropriately.
How to clean parts when dirt is stuck

If any dirt or dust sticks the parts of the fuel system, clean it off thoroughly with clean fuel.
Precautions for replacing fuel filter cartridge
Be sure to use the Komatsu genuine fuel filter cartridge.
NOTICE
The machine equipped with common rail fuel injection system (CRI) consists of more precise parts than
the parts used in the conventional fuel injection pump and nozzle. In order to prevent foreign material
from entering this system, the filter employs a specially high performance of filter element. If a filter oth-
er than a Komatsu genuine filter is used, fuel system contamination and damage may occur. Therefore
Komatsu recommends using only Komatsu fuel filters and install them following the procedures in the
shop manual.
114E-6 SERIES 00-39

PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 00 INDEX AND FOREWORD
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT

The machines equipped with Variable Geometry Turbocharger (VGT) consists of more precise parts (variable
system)than the parts used in the conventional turbocharger. If foreign material enters this system, it may cause
a failure. Use special care to prevent entry of the foreign material when servicing the intake system.
Avoid the work of adding hydraulic oil, replacing filters, or repairing the machine in rainy or windy weather, or in
dusty environment.
Sealing the opening
Plug the removed pipes and the openings of the removed components with the caps, tapes, plastic bags, etc. to
prevent foreign material from entering.
NOTICE
Do not expose the openings or stuff it, otherwise foreign material may enter it.
00-40 114E-6 SERIES

00 INDEX AND FOREWORD DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER

REMARK
• Loosen the oil filler cap of the hydraulic tank slowly to release the remaining pressure in the hydraulic tank.
• Provide an oil container to receive oil since some hydraulic oil flows out when the hose is disconnected even
after the remaining pressure is released from the hydraulic tank.
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE

COUPLER
Disconnection
1. Hold adapter (1), and push hose joint (2) into mating
adapter (3).
REMARK
• Push it in approximately 3.5 mm.
• Do not hold rubber cap portion (4).
2. While having adapter (3) inserted into hose side joint (2),
insert rubber cap (4) to adapter (3) side until it clicks.
3. Hold hose adapter (1) or hose (5), and pull it out.

REMARK
Provide an oil container to receive a quantity of hydraulic
oil which may flow out.
Connection
1. Hold hose adapter (1) or hose (5), and insert it in mating
adapter (3), aligning the axis.
REMARK
Do not hold rubber cap portion (4).
114E-6 SERIES 00-41

DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 00 INDEX AND FOREWORD
2. After inserting the hose in the mating adapter perfectly, pull

it back to check the connecting condition.
REMARK
When the hose fitting is pulled back, the rubber cap moves
approximately 3.5 mm toward the hose, but it is not a prob-
lem.

COUPLER
Disconnection
1. Hold the tightening adapter part and push body (2) straight
until sliding prevention ring (1) contacts contact surface (a)
of the hexagonal part at the male end.
2. While keeping the condition of step 1, turn lever (3) to the

right (clockwise).
3. While keeping the conditions of steps 1 and 2, pull out

whole body (2) to disconnect it.
REMARK
Provide an container to receive a quantity of hydraulic oil
which may flow out.
00-42 114E-6 SERIES

00 INDEX AND FOREWORD DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER
Connection
Hold the tightening adapter part, and push body (2) straight un-
til sliding prevention ring (1) contacts contact surface (a) of the
hexagonal part at the male end.

COUPLER
Disconnection
1. Hold the tightening adapter part and push body (2) straight
until sliding prevention ring (1) contacts contact surface (a)
of the hexagonal part at the male end.
2. While keeping the condition of step 1, push cover (3)

straight until it contacts contact surface (a) of the hexago-
nal portion on the male side.
3. While keeping the conditions of steps 1 and 2, pull out

whole body (2) to disconnect it.
REMARK
Provide an container to receive a quantity of hydraulic oil
which may flow out.
114E-6 SERIES 00-43

DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 00 INDEX AND FOREWORD
Connection
Hold the tightening adapter part, and push body (2) straight un-
til sliding prevention ring (1) contacts contact surface (a) of the
hexagonal part at the male end.
00-44 114E-6 SERIES

PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CON-
00 INDEX AND FOREWORD NECTORS
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNEC-

TORS
Disconnecting connectors
1. Hold the connectors when disconnecting.
When disconnecting the connectors, always hold the con-
necting portion. If the connector is fixed with screw, loosen
the screw of the connector completely, hold the both of
male and female connectors, and pull them out in parallel.
NOTICE
Do not pull the connectors with one hand.
REMARK
If it is a lock stopper type connector, pull it out as pushing
the stopper (1) with your thumb.
2. When removing a connector from a clip
• Both of the connector and clip have stoppers (2),
which are engaged with each other when the connec-
tor is connected.
• When removing a connector from a clip, pull the con-
nector in parallel with the clip as removing stoppers.
NOTICE
If the connector is pried up and down or to the
right or left, it may break the housing.
3. Action to be taken after removing connectors

After removing the connector, cover it with plastic bags to
prevent entry of dust, dirt, oil, or water in the contact por-
tion.
NOTICE
Be sure to cover the connector with plastic bags when
leaving the machine disassembled for a long time, oth-
erwise defective contact may occur.
Connecting connectors
1. Check the connector visually.
• Check that there is no dust, dirt, oil, or water stuck to the connector pins (joint portion).
114E-6 SERIES 00-45

NECTORS 00 INDEX AND FOREWORD
• Check that there is no deformation, defective contact, corrosion, or damage on the connector pins.
• Check that there is no damage or crack on the external surfaces of the connectors.
NOTICE
• If there is any dust, dirt, oil, or water stuck to the connector, wipe it off with a dry cloth. If there is
any water intrusion into the connector, warm the inside of the connector and harness with a dry-
er. Do not overheat the connector, otherwise short circuit may occur.
• If there is any damage or breakage, replace the connector.
2. Connecting the connector securely
Position connector (1) correctly, and fit it in securely.
REMARK
If the connector is lock stopper type, insert it until it clicks.
3. Correct the protrusion of the boot and misalignment of the
wiring harness.
• If the connector is with the boot, correct any extrusion of the boot. In addition, if the wiring harness is
misaligned or the clamp is out of position, adjust it to its correct position.
REMARK
If the protrusion of the boot and misalignment of the
wiring harness cannot be fixed, remove the clamp to
adjust them.
• If the connector clamp is removed, be sure to return it

to its original position. Check that there is no loose-
ness.
Drying wiring harness

REMARK
If the wiring harness is dirty with oil and dust, wipe it off with a dry cloth. Avoid water washing or steam washing.
If water washing is unavoidable, do not use high-pressure water or steam directly on the wiring harness. If water
gets directly on the connector, do as follows.
00-46 114E-6 SERIES

00 INDEX AND FOREWORD NECTORS
1. Disconnect the connector and wipe off the water with a dry
cloth.
NOTICE
If the connector is to be blown with dry compressed
air, there is the risk that oil in the air may cause defec-
tive contact, remove oil and water in the air before
starting air blow.
2. Dry the inside of the connector with a dryer.

If water enters inside the connector, use a dryer to dry the
connector.
NOTICE
Hot air from a dryer can be used, but limit the time of
using a dryer to prevent the connector or related parts
from becoming too hot, as this will cause deformation
or damage to the connector.
3. Perform a continuity test on the connector.

After drying, leave the wiring harness disconnected, con-
nect T-adapter(1), and perform a continuity test to check
for any short circuits between pins caused by water or etc.
REMARK
After the connector is completely dried, blow the contact
restorer, and reassemble them.
Handling controller
k When performing arc welding on the machine body, disconnect all of the wiring harness connectors
connected to the controller. Fit an arc welding ground close to the welding point.
114E-6 SERIES 00-47

NECTORS 00 INDEX AND FOREWORD
NOTICE
• Controller has been assembled with electronic circuits
for control including microcomputers. These electronic
circuits inside of the controller must be handled with
care since they control the machine.
• Do not leave things on the controller.
• Cover the connector portion of the controller with a
tape and a plastic bag. Do not touch the connecting
portion of connector.
• Do not leave the controller in a place where it is ex-
posed to rain.
• Do not place the controller on oil, water, soil or any pla-
ces where the temperature is likely to be high even for
a short period of time (Place it on a suitable dry stand).
Precautions for troubleshooting electrical circuits

• Be sure to turn the starting switch to OFF position before disconnecting or connecting the connectors.
• Before performing troubleshooting, check all the related connectors for loose connection.
REMARK
Check the related connectors for their performance by disconnecting and connecting them several times.
• Be sure to connect all the disconnected connectors before proceeding to the next step.
NOTICE
If the starting switch is turned to ON position while the connectors are disconnected, an unrelated
failure beside the actual failed part may be displayed.
• When performing the troubleshooting for the circuit (measurement of voltage, resistance,continuity, current,
etc.), shake the related wiring harnesses and connectors several times and check that the multimeter read-
ing does not change.
NOTICE
If the value changes on the multimeter, there may be a defective contact in the circuit.
00-48 114E-6 SERIES

METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH
00 INDEX AND FOREWORD CONNECTOR
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNEC-

TOR
Method for disconnecting Deutsch connector
While pressing locks (a) and (b) from each side respectively,
pull out female connector (2).
Method for connecting Deutsch connector

1. Push in female connector (2) horizontally, and insert it
straight until it clicks. (Arrow: x)
2. In order to check whether locks (a) and (b) are completely
inserted, insert female connector (2) by rocking it vertically
(in the arrow z direction). (Arrow: x, y, z)
REMARK
Lock (a) in the figure is pulled down (not set completely),
and lock (b) is set completely.
114E-6 SERIES 00-49

METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK
TYPE CONNECTOR 00 INDEX AND FOREWORD
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE

CONNECTOR
Method for disconnecting slide lock type connector (FRAMATOME-3, FRAMA-
TOME-2)
1. Slide lock (L1) to the right.
2. While pressing lock (L2), pull out connector (1) toward you.
REMARK
If portion A does not float when lock (L2) is pressed, and if
connector (1) does not come out when it is pulled toward
you, push up portion A with a small flat-head screwdriver
while pressing lock (L2), and then pull out connector (1) to-
ward you.
Method for connecting slide lock type connector (FRAMATOME-3, FRAMA-

TOME-2)
Insert it straight until it clicks.
Method for disconnecting slide lock type connector (FRAMATOME-24)

1. Slide down lock (red) (L1).
00-50 114E-6 SERIES

METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK
00 INDEX AND FOREWORD TYPE CONNECTOR
2. While pressing lock (L2), pull out connector (1).

REMARK
Lock (L2) is located behind connector (1) in the figure.
Method for connecting slide lock type connector (FRAMATOME-24)

114E-6 SERIES 00-51

METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR
WITH LOCK TO PULL 00 INDEX AND FOREWORD
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH

LOCK TO PULL
Method for disconnecting connector with lock to pull
Disconnect the connector (2) by pulling lock (B) (on the wiring
harness side) of connector (2) outward.
Method for connecting connector with lock to pull

Insert the connector securely until it "clicks".
00-52 114E-6 SERIES

00 INDEX AND FOREWORD WITH LOCK TO PUSH

LOCK TO PUSH
Method for disconnecting connector with lock to push (BOSCH-3)
While pressing lock (C), pull out connector (3) in the direction of the arrow.
• 114 series
• 107 series
REMARK
If the lock is located on the underside, use flat-head screwdriver [1] since you cannot insert your fingers.
While pushing up lock (C) of the connector with flat-head
screwdriver [1], pull out connector (3) in the direction of the ar-
row.
Method for connecting connector with lock to push (BOSCH-3)

114E-6 SERIES 00-53

WITH LOCK TO PUSH 00 INDEX AND FOREWORD
Method for disconnecting connector with lock to push (AMP-3)

While pressing lock (E), pull out connector (5) in the direction of
the arrow.
Method for connecting connector with lock to push (AMP-3)

Method for disconnecting connector with lock to push (SUMITOMO-3)

While pressing lock (E), pull out connector (5) in the direction of
the arrow.
REMARK
Pull up the connector straight.
Method for connecting connector with lock to push (SUMITOMO-3)

Method for disconnecting connector with lock to push (SUMITOMO-4)

While pressing lock (D), pull out connector (4) in the direction
of the arrow.
Method for connecting connector with lock to push (SUMITOMO-4)

00-54 114E-6 SERIES

00 INDEX AND FOREWORD WITH HOUSING TO ROTATE

HOUSING TO ROTATE
Method for disconnecting connector with housing to rotate
Turn housing (H1) to the left, and pull it out.
REMARK
Housing (H1) is left on the wiring harness side.
Method for connecting connector with housing to rotate

1. Insert the connector to the end while aligning its groove to the other.
2. Turn housing (H1) clockwise until it clicks.
114E-6 SERIES 00-55

HOW TO READ ELECTRICAL WIRE CODE 00 INDEX AND FOREWORD
HOW TO READ ELECTRICAL WIRE CODE

In the electrical circuit diagram, the material, thickness, and color of each electric wire are indicated by symbols.
The electrical wire code is helpful in understanding the electrical circuit diagram.
Example) AEX 0.85 L: Indicates heat-resistant, low-voltage blue wire for automobile, having nominal No. of 0.85
Indicates type of wire by symbol.
Type, symbol, and material of wire are shown in (Table 1).
AEX
(Since the use of AV and AVS wires depends on size (nominal No.), the symbols are not indicated on
the diagram.)
Indicates size of wire by nominal No.
0.85
Sizes (Nominal Nos.) are shown in (Table 2).
Indicates color of wire by color code.
L
Color codes are shown in (Table 3).
Type, symbol, and material

AV and AVS are different in only thickness and outside diameter of the coating. CAVS has a circular com-
pressed conductor. It differs from AV and AVS in the outside diameter of conductor and thickness of the coating.
AEX is similar to AV in thickness and outside diameter of the coating but different from AV and AVS in material
of the coating.
(Table 1)
Temperature
Sym- Conductor ma-
Type Insulator material range (°C) in Example of use
bol terial
use
Low-voltage For large current wiring
wire for auto- AV
mobile (nominal No. 5 and above)
Thin-cover
low-voltage
General wiring
wire for auto- AVS
mobile (nominal No. 3 and lower)
Soft polyvinyl chloride -30 to +60
(Type 1)
Annealed cop-
Thin-cover per for electric
low-voltage appliance For mid- to small-size excava-
wire for auto- CAVS tors
mobile (nominal No. 1.25 and lower)
(Type 2)
Heat-resistant General wiring for extremely

low-voltage Heat-resistant cross- cold weather specification
AEX -50 to +110
wire for auto- linked polyethylene Wiring at high-temperature
mobile place
00-56 114E-6 SERIES

00 INDEX AND FOREWORD HOW TO READ ELECTRICAL WIRE CODE
Dimensions
(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5
Number of
20 7 30 11 50 16 37 26 58 41 65
strands
Diameter of
0.18 0.32 0.18 0.32 0.18 0.32 0.26 0.32 0.26 0.32 0.32
strand
Conductor
Cross-sec-
tional area 0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
( mm2)
d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0
AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 -
Coating D
AV Standard - - - - - - - 4.6
AEX Standard 2.0 2.2 2.7 3.0 3.1 - 3.8 4.6
Nominal No. 8 15 20 30 40 50 60 85 100

Number of
50 84 41 70 85 108 127 169 217
strands
Diameter of
0.45 0.45 0.80 0.80 0.80 0.80 0.80 0.80 0.80
strand
Conductor
Cross-sec-
tional area 7.95 13.36 20.61 35.19 42.73 54.29 63.84 84.96 109.1
( mm2)
d (approx.) 3.7 4.8 6.0 8.0 8.6 9.8 10.4 12.0 13.6
AVS Standard - - - - - - - - -
Coating D
AV Standard 5.5 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
AEX Standard 5.3 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
Nominal No. 0.5f 0.5 0.75f 0.85 1.25f 1.25

Number of
- 7 - 11 - 16
strands
Diameter of round compres- round compres-
- - round compression
strand sion sion
Conductor
Cross-sec-
tional area - 0.56 - 0.88 - 1.29
( mm2)
d (approx.) - 0.9 - 1.1 - 1.4
114E-6 SERIES 00-57

HOW TO READ ELECTRICAL WIRE CODE 00 INDEX AND FOREWORD
Nominal No. 0.5f 0.5 0.75f 0.85 1.25f 1.25

Coating D
CAVS Standard - 1.6 - 1.8 - 2.1
REMARK
“f” of nominal No. denotes "flexible".
Color codes table
(Table 3)
Color Code Color of wire Color Code Color of wire
B Black LgW Light green and White
Br Brown LgY Light green and Yellow
BrB Brown and Black LR Blue and Red
BrR Brown and Red LW Blue and White
BrW Brown and White LY Blue and Yellow
BrY Brown and Yellow O Orange
Ch Charcoal P Pink
Dg Dark green R Red
G Green RB Red and Black
GB Green and Black RG Red and Green
GL Green and Blue RL Red and Blue
Gr Gray RW Red and White
GR Green and Red RY Red and Yellow
GW Green and White Sb Sky Blue
GY Green and Yellow Y Yellow
L Blue YB Yellow and Black
LB Blue and Black YG Yellow and Green
Lg Light green YL Yellow and Blue
LgB Light green and Black YR Yellow and Red
LgR Light green and Red YW Yellow and White
REMARK
In a color code consisting of 2 colors, the first color is the color of the background and the second color is the
color of the marking.
Example) GW indicates that the background is "Green" and marking is "White".
00-58 114E-6 SERIES

00 INDEX AND FOREWORD HOW TO READ ELECTRICAL WIRE CODE
Types of circuits and color codes

Type of wire AVS, AV, CAVS AEX
Charge R WG - - - - R -
Ground B - - - - - B -
Start R - - - - - R -
Light RW RB RY RG RL - O -
Instrument Y YR YB YG YL YW Y Gr
Signal G GW GR GY GB GL G Br
L LW LR LY LB - L -
Type of circuit Br BrW BrR BrY BrB - - -
Lg LgR LgY LgB LgW - - -
O - - - - - - -
Others Gr - - - - - - -
P - - - - - - -
Sb - - - - - - -
Dg - - - - - - -
Ch - - - - - - -
114E-6 SERIES 00-59

EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 00 INDEX AND FOREWORD
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD

The maintenance standard section shows the judgment criteria whether the equipment or parts should be re-
placed or can be reused when the machine is disassembled for the maintenance. The following terms are the
descriptions of the judgment criteria.
Standard dimension and tolerance
• The finished dimension of a part is slightly different from one to another actually.
• A standard dimension of a finished part is set, and an allowable difference from that dimension is set for the
part.
• The dimension set as the standard is called the standard dimension and the allowable range of difference
from this standard dimension is called "tolerance".
• An indication example of a standard dimension and tolerance is shown in the following table.
(The standard dimension is entered on the left side and the tolerance is entered with a positive or negative
symbol on the right side)
Example:
Standard dimension Tolerance
-0.022
120
-0.126
• The tolerance may be indicated in the text and a table as "standard dimension (upper limit of tolerance/
lower limit of tolerance)."
Example) 120 (-0.022/ -0.126)
• Usually, the dimension of a hole and the dimension of the shaft to be inserted into that hole are indicated by
the same standard dimension and different tolerances of the hole and shaft. The tightness of fit is deter-
mined by the tolerance.
• A dimension indication example of a shaft and hole is shown in the following table.
(The standard dimension is entered on the left side and the tolerance of the shaft is entered with a positive
or negative symbol at the center and that of the hole on the right side)
Tolerance
Standard dimension
Shaft Hole
-0.030 +0.046
60
-0.076 0
00-60 114E-6 SERIES

00 INDEX AND FOREWORD EXPLANATION OF TERMS FOR MAINTENANCE STANDARD
Standard clearance and standard value

• The clearance made when new parts are assembled is
called the standard clearance, which is indicated by the
range from the minimum clearance to the maximum clear-
ance.
• When some parts are repaired, the clearance is generally
adjusted to the standard clearance.
• The values indicating performance and function of new
products or equivalent are called "standard value", which is
indicated by a range or a target value.
• When some parts are repaired, the value of performance/
function is set to the standard value.
Standard interference
• When the diameter of a hole of a part shown in the given standard dimension and tolerance table is smaller
than that of the shaft to be inserted, the difference between those diameters is called "interference".
• Subtract the maximum dimension of the hole from the minimum dimension of the shaft and call it (A). Sub-
tract the minimum dimension of the hole from the maximum dimension of the shaft and call it (B). The range
between (A) and (B) is "standard interference".
• After repairing or replacing some parts, measure the dimension of their hole and shaft and check that the
interference is in the standard range.
Repair limit and allowable value or allowable dimension
• The dimension of parts changes due to the wear or deformation while they are used. When the dimension
changes exceeding certain value, parts cannot be used any longer. This value is called "repair limit".
• If a part is worn to the repair limit, it must be replaced or repaired.
• The performance and function of products lower while they are used. A value with which the product can be
used without causing a problem is called "allowable value" or "allowable dimension".
• A product whose dimension is out of the allowable value, must be repaired. However, since the allowable
values are generally estimated through various tests or experiences in most cases, the judgment must be
made in consideration of the operating condition and customer's requirement.
Allowable clearance
• Parts can be used until the clearance between them is increased to a certain limit. The limit at which those
parts cannot be used is called "allowable clearance".
• If the clearance between the parts exceeds the allowable clearance, they must be replaced or repaired.
Allowable interference
• The allowable maximum interference between the hole of a part and the shaft of another part to be assem-
bled is called "allowable interference".
• The allowable interference shows the repair limit of the part of smaller tolerance.
114E-6 SERIES 00-61

EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 00 INDEX AND FOREWORD
• The parts whose interferences are out of the allowable interference must be replaced or repaired.
00-62 114E-6 SERIES

00 INDEX AND FOREWORD STANDARD TIGHTENING TORQUE TABLE
STANDARD TIGHTENING TORQUE TABLE

Table of tightening torque for bolts and nuts
REMARK
Tighten the metric nuts and bolts to the torque shown in the table below unless otherwise specified.
Thread diameter Width across flats

Tightening torque ( Nm { kgm} )
( mm) ( mm)
10
6 11.8 to 14.7 {1.2 to 1.5}
(*2) 10
13
8 27 to 34 {2.8 to 3.5}
(*2) 12
17
10 59 to 74 {6 to 7.5}
(*1, *2) 14
19
12 98 to 123 {10 to 12.5}
(*1, *2) 17
14 22 153 to 190 {15.5 to 19.5}
24
16 235 to 285 {23.5 to 29.5}
(*1) 22
18 27 320 to 400 {33 to 41}
20 30 455 to 565 {46.5 to 58}
22 32 610 to 765 {62.5 to 78}
24 36 785 to 980 {80 to 100}
27 41 1150 to 1440 {118 to 147}
30 46 1520 to 1910 {155 to 195}
33 50 1960 to 2450 {200 to 250}
36 55 2450 to 3040 {250 to 310}
39 60 2890 to 3630 {295 to 370}
*1: Split flange bolt

*2: Flanged bolt
REMARK
Tighten the flanged bolt marked with “7” on the head as shown in the following to the tightening torque shown in
the table below.
114E-6 SERIES 00-63

STANDARD TIGHTENING TORQUE TABLE 00 INDEX AND FOREWORD
Thread diameter Width across flats

Tightening torque ( Nm { kgm} )
( mm) ( mm)
6 10 5.9 to 9.8 {0.6 to 1.0}
8 12 13.7 to 23.5 {1.4 to 2.4}
10 14 34.3 to 46.1 {3.5 to 4.7}
12 17 74.5 to 90.2 {7.6 to 9.2}
REMARK
Tighten the unified coarse threaded bolts and nuts to the torque shown in the table below unless otherwise
specified.
Type of bolt A B
Nominal size - Tightening torque ( Nm { kgm} ) Tightening torque ( Nm { kgm} )

threads per inch Range Target Range Target
1/ 9.8 to 14.7 {1 to 1.5} 12.7 {1.3} 2.9 to 3.9 {0.3 to 0.4} 3.43 {0.35}
4-20UNC
5/ 24.5 to 34.3 {2.5 to 3.5} 29.4 {3} 6.9 to 8.8 {0.7 to 0.9} 7.8 {0.8}
16-18UNC
3/ 44.1 to 58.8 {4.5 to 6} 52.0 {5.3} 9.8 to 14.7 {1 to 1.5} 11.8 {1.2}
8-16UNC
7/ 73.5 to 98.1 {7.5 to 10} 86.3 {8.8} 19.6 to 24.5 {2 to 2.5} 21.6 {2.2}
16-14UNC
1/ 108 to 147 {11 to 15} 127 {13} 29.4 to 39.2 {3 to 4} 34.3 {3.5}
2-13UNC
9/ 157 to 216 {16 to 22} 186 {19} 44.1 to 58.8 {4.5 to 6} 51.0 {5.2}
16-12UNC
5/ 226 to 294 {23 to 30} 265 {27} 63.7 to 83.4 {6.5 to 8.5} 68.6 {7}
8-11UNC
3/ -10UNC 392 to 530 {40 to 54} 461 {47} 108 to 147 {11 to 15} 127 {13}
4
7/ 637 to 853 {65 to 87} 745 {76} 177 to 235 {18 to 24} 206 {21}
8-9UNC
00-64 114E-6 SERIES

Type of bolt A B

1-8UNC 883 to 1196 {90 to 122} 1040 {106} 245 to 333 {25 to 34} 284 {29}
11/8-7UNC 1187 to 1608 {121 to 164} 1393 {142} 333 to 451 {34 to 46} 392 {40}
11/4-7UNC 1598 to 2157 {163 to 220} 1873 {191} 451 to 608 {46 to 62} 530 {54}
11/2-6UNC 2354 to 3177 {240 to 324} 2765 {282} 657 to 892 {67 to 91} 775 {79}
REMARK
Tighten the unified fine threaded bolts and nuts to the torque shown in the table below unless otherwise speci-
fied.
Type of bolt A B

1/ 14.7 to 19.6 {1.5 to 2} 17.7 {1.8} 3.9 to 4.9 {0.4 to 0.5} 4.41 {0.45}
4-28UNF
5/ 34.3 to 39.2 {3.5 to 4} 34.3 {3.5} 7.8 to 9.8 {0.8 to 1} 8.8 {0.9}
16-24UNF
3/ 53.9 to 68.6 {5.5 to 7} 61.8 {6.3} 14.7 to 19.6 {1.5 to 2} 16.7 {1.7}
8-24UNF
7/ 83.4 to 108 {8.5 to 11} 96.1 {9.8} 24.5 to 29.4 {2.5 to 3} 26.5 {2.7}
16-20UNF
1/ 127 to 167 {13 to 17} 147 {15} 34.3 to 49.0 {3.5 to 5} 41.2 {4.2}
2-20UNF
9/ 186 to 245 {19 to 25} 216 {22} 49.0 to 68.6 {5 to 7} 58.8 {6}
16-18UNF
5/ 255 to 343 {26 to 35} 294 {30} 73.5 to 98.1 {7.5 to 10} 83.4 {8.5}
8-18UNF
3/ 441 to 598 {45 to 61} 520 {53} 127 to 167 {13 to 17} 147 {15}
4-16UNF
7/ 716 to 961 {73 to 98} 843 {86} 196 to 265 {20 to 27} 226 {23}
8-14UNF
1-14UNF 1020 to 1373 {104 to 140} 1196 {122} 284 to 382 {29 to 39} 333 {34}
11/8-12UNF 1353 to 1844 {138 to 188} 1598 {163} 382 to 520 {39 to 53} 451 {46}
11/4-12UNF 1804 to 2432 {184 to 248} 2118 {216} 510 to 686 {52 to 70} 598 {61}
11/2-12UNF 2707 to 3658 {276 to 373} 3177 {324} 765 to 1030 {78 to 105} 892 {91}
114E-6 SERIES 00-65

Table of tightening torque for O-ring boss piping joints

REMARK
Tighten the pipe joint for O-ring boss to the torque shown in the table below unless otherwise specified.
Thread di- Tightening torque ( Nm { kgm} )

Width across
Nominal No. ameter
flats ( mm) Range Target
( mm)
02 14 35 to 63 {3.5 to 6.5} 44 {4.5}
- 18 59 to 98 {6.0 to 10.0} 78 {8.0}
Varies de-
03, 04 20 pending on 84 to 132 {8.5 to 13.5} 103 {10.5}
05, 06 24 type of con- 128 to 186 {13.0 to 19.0} 157 {16.0}
nector.
10, 12 33 363 to 480 {37.0 to 49.0} 422 {43.0}
14 42 746 to 1010 {76.0 to 103} 883 {90.0}
Table of tightening torque for O-ring boss plugs

REMARK
Tighten the plug for O-ring boss to the torque shown in the table below unless otherwise specified.
Thread diam- Width across Tightening torque ( Nm { kgm} )

Nominal No.
eter ( mm) flats ( mm) Range Target
08 8 14 5.88 to 8.82 {0.6 to 0.9} 7.35 {0.75}
10 10 17 9.8 to 12.74 {1.0 to 1.3} 11.27 {1.15}
12 12 19 14.7 to 19.6 {1.5 to 2.0} 17.64 {1.8}
14 14 22 19.6 to 24.5 {2.0 to 2.5} 22.54 {2.3}
16 16 24 24.5 to 34.3 {2.5 to 3.5} 29.4 {3.0}
00-66 114E-6 SERIES

Thread diam- Width across Tightening torque ( Nm { kgm} )

Nominal No.
eter ( mm) flats ( mm) Range Target
18 18 27 34.3 to 44.1 {3.5 to 4.5} 39.2 {4.0}
20 20 30 44.1 to 53.9 {4.5 to 5.5} 49.0 {5.0}
24 24 32 58.8 to 78.4 {6.0 to 8.0} 68.6 {7.0}
30 30 32 93.1 to 122.5 {9.5 to 12.5} 107.8 {11.0}
33 33 - 107.8 to 147.0 {11.0 to 15.0} 127.4 {13.0}
36 36 36 127.4 to 176.4 {13.0 to 18.0} 151.9 {15.5}
42 42 - 181.3 to 240.1 {18.5 to 24.5} 210.7 {21.5}
52 52 - 274.4 to 367.5 {28.0 to 37.5} 323.4 {33.0}
Table of tightening torque for hose (taper seal type and face seal type)
REMARK
• Tighten the hose fittings (taper seal type and face seal type) to the torque shown in the following table un-
less otherwise specified.
• The table is applied to the threaded portion coated with engine oil (wet threaded portion).
Width Tightening torque ( Nm { kgm} ) Taper seal Face seal

Nominal
across Nominal size - Thread root
No. of Thread size
flats Range Target threads per diameter( mm)
hose ( mm)
( mm) inch (reference)
34 to 54 {3.5 to 5.5} 44 {4.5} - 9/ 14.3
16-18UN
02 19
34 to 63 {3.5 to 6.5} 44 {4.5} 14 - -
22 54 to 93 {5.5 to 9.5} 74 {7.5} - 11/ 17.5
16-16UN
03
24 59 to 98 {6.0 to 10.0} 78 {8.0} 18 - -
04 27 84 to 132 {8.5 to 13.5} 103 {10.5} 22 13/ -16UN 20.6
16
05 32 128 to 186 {13.0 to 19.0} 157 {16.0} 24 1 -14UNS 25.4

06 36 177 to 245 {18.0 to 25.0} 216 {22.0} 30 13/16-12UN 30.2
(10) 41 177 to 245 {18.0 to 25.0} 216 {22.0} 33 - -
(12) 46 197 to 294 {20.0 to 30.0} 245 {25.0} 36 - -
(14) 55 246 to 343 {25.0 to 35.0} 294 {30.0} 42 - -
114E-6 SERIES 00-67

Table of tightening torque for face seal joints

REMARK
• The tightening torque table below applies to the seal joint (sleeve nut type) made with steel pipe for plated
low pressure piping which is used for engine.
• The table is applied to the threaded portion coated with engine oil (wet threaded portion).
• Reference: The face seal joint of the dimension in ( ) is also used depending on the specification.
Outside di- Tightening torque ( Nm { kgm} ) Face seal

Width
ameter of Thread root diam-
across flats Nominal size -
adequate Range Target eter( mm) (refer-
( mm) threads per inch
pipe ( mm) ence)
8 19 14 to 16 {1.4 to 1.6} 15 {1.5} 9/ 14.3
16-18UN
10 22 24 to 27 {2.4 to 2.7} 25.5 {2.6} 11/ -16UN 17.5

16
12 24 (27) 43 to 47 {4.4 to 4.8} 45 {4.6} 13/ 20.6

16-16UN
15 (16) 30 (32) 60 to 68 {6.1 to 6.8} 64 {6.5} 1 -14UNS 25.4

22 (20) 36 90 to 95 {9.2 to 9.7} 92.5 {9.4} 13/16-12UN 30.2
Tightening torque table for bolts and nuts on 102, 107 and 114 series engines
REMARK
Tighten the metric threads bolts and nuts used on the 102, 107 and 114 series engines to the torques shown in
the following table unless otherwise specified.
Thread diameter ( mm) Tightening torque ( Nm { kgm} )
6 10±2 {1.02±0.20}
8 24±4 {2.45±0.41}
10 43±6 {4.38±0.61}
12 77±12 {7.85±1.22}
14 -
Tightening torque table for 102, 107, and 114 series engines (joint bolts)
REMARK
Tighten the metric joint bolts used on the 102, 107, and 114 series engines to the torque shown in the following
table unless otherwise specified.
00-68 114E-6 SERIES

Thread diameter ( mm) Tightening torque ( Nm { kgm} )

6 8±2 {0.81±0.20}
8 10±2 {1.02±0.20}
10 12±2 {1.22±0.20}
12 24±4 {2.45±0.41}
14 36±5 {3.67±0.51}
Tightening torque table for tapered screws on 102, 107, and 114 series engines
(National taper pipe thread (NPT))
REMARK
Tighten the National taper pipe threaded (NPT) screws used on the 102, 107, and 114 series engines to the
torques shown in the following table unless otherwise specified.
Material of female screw In cast iron or steel In aluminum
Nominal thread size Tightening torque ( Nm { kgm} ) Tightening torque ( Nm { kgm} )
1/ 15±2 {1.53±0.20} 5±1 {0.51±0.10}
16
1/ 20±2 {2.04±0.20} 15±2 {1.53±0.20}

8
1/ 25±3 {2.55±0.31} 20±2 {2.04±0.20}

4
3/ 35±4 {3.57±0.41} 25±3 {2.55±0.31}

8
1/ 55±6 {5.61±0.61} 35±4 {3.57±0.41}

2
3/ 75±8 {7.65±0.82} 45±5 {4.59±0.51}

4
114E-6 SERIES 00-69

CONVERSION TABLE 00 INDEX AND FOREWORD
CONVERSION TABLE
Method of using the conversion table
The conversion table is provided to enable simple conversion of the numerical numbers between the different
units. For further details of the method of using the conversion table, see the examples given below.
Examples of using the conversion table to convert a unit from mm to in.
When converting 55 mm to in
1. Locate the number 50 in the leftmost column, take this as (A), and then draw a horizontal line from (A).
2. Locate the number 5 in the top row, take this as (B), then draw a vertical line down from (B).
3. Take the crossover point of the two lines as (C). This point (C) gives the value when converting the unit
from mm to in. Accordingly, 55 mm = 2.165 in.
When converting 550 mm to in
1. The number 550 does not appear in the table. Divide it by 10 (move the decimal point one place to the left)
to get 55 mm.
2. Convert 55 mm to 2.165 in according to the preceding procedure.
3. The original value (550 mm) has been divided by 10, so multiply 2.165 in by 10 (move the decimal point
one place to the right) to restore the target value. This gives 550 mm = 21.65 in
mm to in
(B)
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
(C)
50 1.969 2.008 2.017 2.087 2.126 2.165 2.205 2.244 2.283 2.323
(A)
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.847 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.780 3.819 3.858 3.898
mm to in
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
00-70 114E-6 SERIES

00 INDEX AND FOREWORD CONVERSION TABLE
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.847 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
kg to lb
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
ℓ to U.S.Gal
1 ℓ = 0.2642 U.S.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
ℓ to U.K.Gal
1 ℓ = 0.21997 U.K.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
114E-6 SERIES 00-71

1 ℓ = 0.21997 U.K.Gal
0 1 2 3 4 5 6 7 8 9
30 6.599 6.819 7.039 7.259 7.479 7.699 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
kgm to lbft
1 kgm = 7.233 lbft
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
kg/cm2 to lb/in2
1 kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
00-72 114E-6 SERIES

00 INDEX AND FOREWORD CONVERSION TABLE
1 kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
Temperature
Conversion of Fahrenheit to Celsius
• A simple way to convert a Fahrenheit temperature reading into a Celsius temperature reading or vice versa
is to see the number in the center column of the following table. The figures in the center of the following
table show the temperatures in both Fahrenheit and Celsius.
• When converting from Fahrenheit to Celsius degrees, consider the center column to be a table of Fahren-
heit temperatures and read the corresponding Celsius temperature in the column at the left.
• When converting from Celsius to Fahrenheit degrees, consider the center column to be a table of Celsius
values, and read the corresponding Fahrenheit temperature on the right.
1 °C = 33.8 °F
°C °F °C °F °C °F °C °F
-40.4 -40 -40.0 -11.7 11 51.8 7.8 46 114.8 27.2 81 177.8
-37.2 -35 -31.0 -11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
-34.4 -30 -22.0 -10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
-31.7 -25 -13.0 -10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
-28.9 -20 -4.0 -9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
-28.3 -19 -2.2 -8.9 16 60.8 10.6 51 123.8 30.0 86 186.8
-27.8 -18 -0.4 -8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
114E-6 SERIES 00-73

1 °C = 33.8 °F
°C °F °C °F °C °F °C °F
-27.2 -17 1.4 -7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
-26.7 -16 3.2 -7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
-26.1 -15 5.0 -6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
-25.6 -14 6.8 -6.1 21 69.8 13.3 56 132.8 32.8 91 195.8
-25.0 -13 8.6 -5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
-24.4 -12 10.4 -5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
-23.9 -11 12.2 -4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
-23.3 -10 14.0 -3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
-22.8 -9 15.8 -3.3 26 78.8 16.1 61 141.8 35.6 96 204.8
-22.2 -8 17.6 -2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
-21.7 -7 19.4 -2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
-21.1 -6 21.2 -1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
-20.6 -5 23.0 -1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
-20.0 -4 24.8 -0.6 31 87.8 18.9 66 150.8 40.6 105 221.0
-19.4 -3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
-18.9 -2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
-18.3 -1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
-17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
-17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0
-16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
-16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
-15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
-15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
-14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0
-13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
-13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
-12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
-12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
00-74 114E-6 SERIES

01 SPECIFICATIONS
114E-6 SERIES 01-1

CONTENTS 01 SPECIFICATIONS
CONTENTS
ABBREVIATION LIST .................................................................................................................................... 01-3
SPECIFICATIONS ......................................................................................................................................... 01-9
OUTLINE OF EXHAUST GAS REGULATION......................................................................................... 01-9
SYSTEM DRAWINGS OF ENGINE CONFORMED TO TIER4 REGULATION............................... 01-10
IMPROVED POINTS OF ENGINE CONFORMED TO TIER4 REGULATION..................................01-11
LIST OF APPLICABLE MACHINES: 114E-6 ......................................................................................... 01-12
SPECIFICATIONS ................................................................................................................................ 01-13
SPECIFICATIONS: SAA6D114E-6 (D65EX-18, D65EX-18E0, D65EXI-18, D65EXI-18E0, D65PX-18,
D65PX-18E0, D65PXI-18, D65PXI-18E0, D65WX-18, D65WX-18E0)........................................ 01-13
SPECIFICATIONS: SAA6D114E-6 (HB365LC-3) ........................................................................... 01-14
SPECIFICATIONS: SAA6D114E-6 (PC360LC-11, PC360LCI-11) .................................................. 01-15
ENGINE GENERAL VIEW .................................................................................................................... 01-16
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) ..................... 01-16
ENGINE GENERAL VIEW: SAA6D114E-6 (HB365LC-3)............................................................... 01-20
ENGINE GENERAL VIEW: SAA6D114E-6 (PC360LC-11, PC360LCI-11) ...................................... 01-24
ENGINE PERFORMANCE CURVE ...................................................................................................... 01-28
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) ........
................................................................................................................................................... 01-28
ENGINE PERFORMANCE CURVE: SAA6D114E-6 (HB365LC-3, PC360LC-11, PC360LCI-11).... 01-29
01-2 114E-6 SERIES

01 SPECIFICATIONS ABBREVIATION LIST
ABBREVIATION LIST
the meaning.
Abbrevia-
tion
component/system)
AISS Engine
System speed.
AJSS
Automatic Retarder
the downhill.
ASR
faces.
BCV
used.
Regulator
used independently.
Closed-center Load
Sensing System
114E-6 SERIES 01-3

ABBREVIATION LIST 01 SPECIFICATIONS

Abbrevia-
tion
component/system)
jector.
EGR Engine
emission of NOx.
tional Control
Structure
Forward-Neutral-Re-
verse
Communication
Plus)
Communication
Plus)
HSS
01-4 114E-6 SERIES


Abbrevia-
tion
component/system)
and communication.
Unit
trol motions.
IMA)
KCCV Engine
filters.

KCSF Engine
KDOC Engine
fler.
late Filter
assembled.
LIN
LVDS
MAF sensor.
114E-6 SERIES 01-5


Abbrevia-
tion
component/system)
Service
system
system
Open-center Load
Sensing System
load.
PCCS
pedals, and dials.
Hydraulic system
(D, PC, etc)
ROPS Cab and canopy
ISO 12117-2.
SCR Urea SCR system
devices.
01-6 114E-6 SERIES


Abbrevia-
tion
component/system)
Structure
tion of flow.
VGT Engine
VHPC Engine control
achieved.

D: Bulldozer
HD: Dump truck
WA: Wheel loader
A/C Air Conditioner
A/M Air Mix Damper
ACC Accessory
ADD Additional
AUX Auxiliary
BR Battery Relay
CW Clockwise
ENG Engine
F.G. Frame Ground
GND Ground
NC No Connection
114E-6 SERIES 01-7


S/T
Steering
STRG
SIG Signal
SOL Solenoid
STD Standard
OPT
Option
OP
PRESS Pressure
SPEC Specification
SW Switch
TEMP Temperature
T/M Transmission
01-8 114E-6 SERIES

01 SPECIFICATIONS OUTLINE OF EXHAUST GAS REGULATION
SPECIFICATIONS
OUTLINE OF EXHAUST GAS REGULATION
• Diesel engines discharge the following 3 major materials
that have bad effects on the human body and environment.
NOx (nitrogen oxides): Respiratory disorder, acid rain
HC (Hydrocarbon): Photochemical smog
PM (particulate in air such as soot): Carcinogenic, respira-
tory disorder
• NOx is material which is produced at high temperature
from nitrogen (N2) and oxygen (O2) in the air. It is pro-
duced in the diesel engine because of excessive air (nitro-
gen). To reduce NOx, the combustion temperature in the
cylinder must be reduced to restrict oxidation of nitrogen.
For this purpose, the air from turbocharger (1) has been
cooled by air-cooled aftercooler (2) and recirculated (EGR
system).
• HC is the main component of the fuel. HC contained in the
blowby gas is the main part of the toxic material dis-
charged from the diesel engine, but it has been discharged
into the atmosphere.
• PM is produced by incomplete combustion of fuel, similarly
to HC. It is particles (solid matter) sticking soot, etc. Gener-
ally, if either of NOx and PM is reduced, the other increas-
es. To reduced PM, common rail (3) is employed, and
electronically controlled high-pressure fuel injection system
is used to spray fuel finely, shorten the injection period, and improve the injection timing.
• Exhaust gas regulations are made and applied in Japan, USA, and EU. The following figure shows the his-
tory of the exhaust gas regulation in USA from Tier 1 to Tier4. (History of exhaust gas regulation by EPA
(*1) of USA (For engine rated horsepower: 130 to 560 kW))
The horizontal axis is NOx + NMHC (*2) and the vertical axis is PM. Discharge levels of both NOx + NMHC
and PM are reduced to almost 1/10 from Tier 3 to Tier 4 Final. This exhaust gas regulation is called "Tier 4
Final Regulation".
*1: United States Environmental Protection Agency
*2: General term for hydrocarbon (HC) which highly causes
photochemical reaction.
114E-6 SERIES 01-9

OUTLINE OF EXHAUST GAS REGULATION 01 SPECIFICATIONS
SYSTEM DRAWINGS OF ENGINE CONFORMED TO TIER4 REGULATION
A: From atmosphere B: To atmosphere

1: Air cleaner 12: Engine oil pan
2: VGT 13: Engine
3: Air-cooled aftercooler 14: Mixing connector(*1)
4: Intake air heater 15: AdBlue/DEF mixing tube(*1)
5: Intake manifold 16: SCR assembly(*1)
6: Exhaust manifold 17: AdBlue/DEF tank(*1)
7: EGR valve 18: AdBlue/DEF pump(*1)
8: KCCV ventilator 19: AdBlue/DEF injector(*1)
9: KDPF 20: Engine controller
10: EGR cooler 21: Various sensors
11: Flywheel housing
*1: This may not be installed on some machine models and specifications.
01-10 114E-6 SERIES

01 SPECIFICATIONS OUTLINE OF EXHAUST GAS REGULATION
IMPROVED POINTS OF ENGINE CONFORMED TO TIER4 REGULATION

Improved points of Tier 4 Interim over Tier 3
• Increase of efficiency of EGR cooler (10) (Reduction of NOx)
• Increase of intake air (reduction of PM) in engine low speed range by variable rotation of turbocharger
(VGT)
• Oxygen density control (reduction of NOx and PM) by EGR ratio (*1) control matched to operating condition
which are attained by high-precision EGR valve (EGRV), intake air flow and temperature sensor (MAF), en-
gine controller, and sensing of various portions of EGR circuit
• Fine fuel injection (reduction of PM) by increase of common rail pressure and fuel injection pressure
• Internal recirculation of blowby gas (reduction of HC) by employment of blowby reducing device (KCCV)
• Employment of soot collecting filter (KCSF) (reduction of PM)
• Improvement of combustion chamber (reduction of NOx, reduction of PM, low fuel consumption)
• High altitude is recognized by ambient pressure sensor (PAMB), and fuel injection and VGT are controlled
automatically (reduction of NOx and PM at high altitude).
• Sensing of rotation of VGT (REV) (protection of VGT)
• Clogging of soot collecting filter (KCSF) is detected by differential pressure (dP) in KDPF, and engine con-
troller performs regeneration *2) as necessary (automatic regeneration) or performance of manual regener-
ation is displayed on machine monitor (maintenance of function of KDPF)
*1: EGR ratio means the ratio of EGR gas contained in the intake gas.
*2: Function to purify (burn) soot accumulated in soot collecting figure (KCSF) in KDPF.
Improved points of Tier 4 Final over Tier 4 Interim
• AdBlue/DEF is sprayed over toxic nitrogen oxides (NOx) contained in exhaust gas to decompose the into
harmless nitrogen and water. Urea SCR system (*3) is employed for this purpose.
*3: Function to purify NOx by making ammonia in AdBlue/DEF react with NOx inside catalyst.
114E-6 SERIES 01-11

LIST OF APPLICABLE MACHINES: 114E-6 01 SPECIFICATIONS
LIST OF APPLICABLE MACHINES: 114E-6

Engine Applicable machine
D65EX-18
D65EX-18E0
D65EXI-18
D65EXI-18E0
D65PX-18
Bulldozer
D65PX-18E0
SAA6D114E-6 D65PXI-18
D65PXI-18E0
D65WX-18
D65WX-18E0
HB365LC-3
PC360LC-11 Hydraulic excavator
PC360LCI-11
01-12 114E-6 SERIES

01 SPECIFICATIONS SPECIFICATIONS
SPECIFICATIONS
SPECIFICATIONS: SAA6D114E-6 (D65EX-18, D65EX-18E0, D65EXI-18,
D65EXI-18E0, D65PX-18, D65PX-18E0, D65PXI-18, D65PXI-18E0, D65WX-18,
D65WX-18E0)
Engine model SAA6D114E-6
No. of cylinders - bore x stroke mm 6-114×144.5
Piston displacement ℓ { cc} 8.85 {8850}
Firing order ― 1-5-3-6-2-4
Overall length mm 1132
Overall width mm 934
Dimensions Overall height (excluding

mm 1182
exhaust pipe)
Overall height (including ex-
mm -
haust pipe)
kW { HP} /
Rated horsepower (Gross) 163.8 {219.7}/1950 {1950}
min-1 { rpm}
Nm { kgm} /
Max. torque (Gross) 1050 {107.1}/1450 {1450}
min-1 { rpm}
Performance Max. speed with no load

min-1 { rpm} 2100 ± 50 {2100 ± 50}
(high idle speed)
Min. speed with no load
min-1 { rpm} 825±25 {825±25}
(low idle speed)
Fuel consumption ratio at g/kWh
215 {160.3}
rated point { g/HPh}
Dry weight kg 903
Fuel injection system ― High-pressure common rail type
Control of fuel injection system ― Electronic control type
Lubricating oil amount (Refill capacity) ℓ 34.5 (30.5)
Amount of coolant ℓ 12.8
Alternator ― 24 V, 90 A
Starting motor ― 24 V,7.5 kW or 11 kW
VGT (Turbocharger) ― HOLSET HE400VG
114E-6 SERIES 01-13

SPECIFICATIONS 01 SPECIFICATIONS
SPECIFICATIONS: SAA6D114E-6 (HB365LC-3)

Firing order - 1-5-3-6-2-4

mm 1286
exhaust pipe)
mm -
haust pipe)
kW { HP} /
Rated horsepower (Gross) 202 {271}/1950 {1950}
min-1 { rpm}
Nm { kgm} /
Max. torque (Gross) 1171 {119}/1450 {1450}
min-1 { rpm}

min-1 { rpm} 2050 ± 30 {2050 ± 30}
(high idle speed)
min-1 { rpm} 700±25 {700±25}
(low idle speed)
216 {161}
Dry weight (aftertreatment devices are not includ-
kg 950
ed)
Fuel injection system - High-pressure common rail type
Control of fuel injection system - Electronic control type
Alternator - 24 V, 90 A
Starting motor - 24 V,7.5 kW or 11 kW
VGT (Turbocharger) - HOLSET HE431Vh
01-14 114E-6 SERIES

01 SPECIFICATIONS SPECIFICATIONS
SPECIFICATIONS: SAA6D114E-6 (PC360LC-11, PC360LCI-11)

Firing order ― 1-5-3-6-2-4

mm 1230
exhaust pipe)
mm -
haust pipe)
kW { HP} /
Rated horsepower (Gross) 202 {271}/1950 {1950}
min-1 { rpm}
Nm { kgm} /
Max. torque (Gross) 1171 {119}/1450 {1450}
min-1 { rpm}

min-1 { rpm} 2050 ± 30 {2050 ± 30}
(high idle speed)
min-1 { rpm} 1000±25 {1000±25}
(low idle speed)
212 {156}
Dry weight (aftertreatment devices are not includ-
kg 910
ed)
Fuel injection system ― High-pressure common rail type
Control of fuel injection system ― Electronic control type
Alternator ― 24 V, 90 A
Starting motor ― 24 V,11 kW or 7.5 kW
VGT (Turbocharger) ― HOLSET HE431Vh
114E-6 SERIES 01-15

ENGINE GENERAL VIEW 01 SPECIFICATIONS
ENGINE GENERAL VIEW

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)
REMARK
The shape is subject to machine models.
Left side view
1: Center of crankshaft
2: Rear face of flywheel housing
01-16 114E-6 SERIES

01 SPECIFICATIONS ENGINE GENERAL VIEW
Dimension (A) : 1409 mm

Right side view
114E-6 SERIES 01-17

Front view
2: Center of cylinder
Dimension (B): 1651 mm
Dimension (C): 402 mm
Dimension (D): 952 mm
01-18 114E-6 SERIES

Rear view
114E-6 SERIES 01-19

ENGINE GENERAL VIEW: SAA6D114E-6 (HB365LC-3)

REMARK
Left side view
Dimension (A): 1210 mm
01-20 114E-6 SERIES

Right side view
114E-6 SERIES 01-21

Front view
01-22 114E-6 SERIES

Rear view
114E-6 SERIES 01-23

ENGINE GENERAL VIEW: SAA6D114E-6 (PC360LC-11, PC360LCI-11)

REMARK
Left side view
Dimension (A): 1362 mm
01-24 114E-6 SERIES

Right side view
114E-6 SERIES 01-25

Front view
01-26 114E-6 SERIES

Rear view
114E-6 SERIES 01-27

ENGINE PERFORMANCE CURVE 01 SPECIFICATIONS
ENGINE PERFORMANCE CURVE

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)
Rated output: 163.8 kW {219.7 HP} /1950 min-1 {1950 rpm} (Gross)
Max. torque: 1050 Nm {107.1 kgm} /1450 min-1 {1450 rpm} (Gross)
1200
1000
800
Torque (Nm)
600
400
200
0
200
180
160
Flywheel horsepower (kW)
140
120
100
80
60
40
20
Engine speed (min-1)
*
01-28 114E-6 SERIES

01 SPECIFICATIONS ENGINE PERFORMANCE CURVE
ENGINE PERFORMANCE CURVE: SAA6D114E-6 (HB365LC-3, PC360LC-11,

PC360LCI-11)
Rated output: 202 kW {271 HP} /1950 min-1 {1950 rpm} (Gross)
Max. torque: 1171 Nm {119 kgm} /1450 min-1 {1450 rpm} (Gross)
1400
1200
1000
Torque (Nm)
800
600
400
200
0
220
200
180
160
Flywheel horsepower (kW)
140
120
100
80
60
40
20
Engine speed (min-1)

$(
114E-6 SERIES 01-29

10 STRUCTURE AND FUNCTION
114E-6 SERIES 10-1

CONTENTS 10 STRUCTURE AND FUNCTION
CONTENTS
UREA SCR SYSTEM................................................................................................................................... 10-10
LAYOUT DRAWING OF UREA SCR SYSTEM ..................................................................................... 10-10
UREA SCR SYSTEM DIAGRAM .......................................................................................................... 10-12
FUNCTION OF UREA SCR SYSTEM................................................................................................... 10-14
FUNCTION OF AdBlue/DEF SUPPLY SYSTEM ............................................................................ 10-14
INDUCEMENT STRATEGY ........................................................................................................... 10-17
COMPONENT PARTS OF UREA SCR SYSTEM.................................................................................. 10-31
AdBlue/DEF MIXING TUBE ........................................................................................................... 10-31
SCR ASSEMBLY ........................................................................................................................... 10-32
AdBlue/DEF TANK ......................................................................................................................... 10-34
AdBlue/DEF PUMP ........................................................................................................................ 10-36
AdBlue/DEF INJECTOR................................................................................................................. 10-37
AdBlue/DEF HOSE ........................................................................................................................ 10-38
AdBlue/DEF TANK HEATING VALVE............................................................................................. 10-39
ENGINE SYSTEM ....................................................................................................................................... 10-40
LAYOUT OF ENGINE COMPONENTS ................................................................................................. 10-40
LAYOUT DRAWING OF ENGINE COMPONENTS ........................................................................ 10-40
INTAKE AND EXHAUST SYSTEM PARTS ........................................................................................... 10-42
LAYOUT DRAWING OF INTAKE AND EXHAUST SYSTEM.......................................................... 10-42
INTAKE AND EXHAUST SYSTEM CIRCUIT DIAGRAM................................................................ 10-43
FUNCTION OF INTAKE AND EXHAUST SYSTEM ....................................................................... 10-43
AIR CLEANER ............................................................................................................................... 10-45
INTAKE AIR HEATER .................................................................................................................... 10-46
ENGINE MAIN BODY PARTS............................................................................................................... 10-47
CYLINDER HEAD .......................................................................................................................... 10-47
CYLINDER BLOCK........................................................................................................................ 10-49
MAIN MOVING PARTS .................................................................................................................. 10-51
VIBRATION DAMPER.................................................................................................................... 10-54
TIMING GEAR ............................................................................................................................... 10-55
FRONT COVER............................................................................................................................. 10-56
VALVE SYSTEM ............................................................................................................................ 10-57
FLYWHEEL AND FLYWHEEL HOUSING ...................................................................................... 10-58
TURBOCHARGER SYSTEM ................................................................................................................ 10-59
CIRCUIT DIAGRAM OF VGT SYSTEM ......................................................................................... 10-59
FUNCTION OF VGT SYSTEM....................................................................................................... 10-60
VGT ............................................................................................................................................... 10-61
EGR SYSTEM ............................................................................................................................... 10-65
EGR VALVE ................................................................................................................................... 10-67
EGR COOLER ............................................................................................................................... 10-69
KCCV SYSTEM ............................................................................................................................. 10-71
KCCV VENTILATOR ...................................................................................................................... 10-75
KDPF ............................................................................................................................................. 10-77
LUBRICATION SYSTEM....................................................................................................................... 10-81
LAYOUT DRAWING OF LUBRICATION SYSTEM PARTS............................................................. 10-81
LUBRICATION SYSTEM CIRCUIT DIAGRAM............................................................................... 10-82
ENGINE OIL PUMP ....................................................................................................................... 10-83
ENGINE BOOST OIL PUMP.......................................................................................................... 10-84
ENGINE OIL FILTER ..................................................................................................................... 10-85
ENGINE OIL COOLER .................................................................................................................. 10-86
SAFETY VALVE OF ENGINE OIL FILTER ..................................................................................... 10-87
ENGINE OIL PAN .......................................................................................................................... 10-88
FUEL SYSTEM ..................................................................................................................................... 10-89
LAYOUT DRAWING OF FUEL SYSTEM PARTS ........................................................................... 10-89
FUEL SYSTEM CIRCUIT DIAGRAM ............................................................................................. 10-90
FUNCTION OF FUEL SYSTEM ..................................................................................................... 10-90
10-2 114E-6 SERIES

10 STRUCTURE AND FUNCTION CONTENTS
SUPPLY PUMP.............................................................................................................................. 10-93

FUEL PREFILTER ......................................................................................................................... 10-96
FUEL MAIN FILTER....................................................................................................................... 10-97
COOLING SYSTEM.............................................................................................................................. 10-98
LAYOUT DRAWING OF COOLING SYSTEM PARTS.................................................................... 10-98
COOLING SYSTEM CIRCUIT DIAGRAM ...................................................................................... 10-99
DRIVE PULLEY ............................................................................................................................10-101
WATER PUMP ..............................................................................................................................10-103
THERMOSTAT..............................................................................................................................10-104
ELECTRICAL SYSTEM ..............................................................................................................................10-105
COMPONENT PARTS OF ELECTRICAL SYSTEM .............................................................................10-105
ALTERNATOR ..............................................................................................................................10-105
STARTING MOTOR ......................................................................................................................10-108
ENGINE WIRING HARNESS........................................................................................................ 10-111
ENGINE CONTROLLER ...............................................................................................................10-113
SENSOR..............................................................................................................................................10-120
LAYOUT DRAWING OF ENGINE SENSOR .................................................................................10-120
STRUCTURE OF AMBIENT PRESSURE SENSOR .....................................................................10-123
FUNCTION OF AMBIENT PRESSURE SENSOR ........................................................................10-123
STRUCTURE OF ENGINE OIL PRESSURE SWITCH .................................................................10-124
FUNCTION OF ENGINE OIL PRESSURE SWITCH .....................................................................10-124
STRUCTURE OF CHARGE (BOOST) PRESSURE AND TEMPERATURE SENSOR ..................10-125
FUNCTION OF CHARGE (BOOST) PRESSURE AND TEMPERATURE SENSOR......................10-125
STRUCTURE OF COOLANT TEMPERATURE SENSOR.............................................................10-126
FUNCTION OF COOLANT TEMPERATURE SENSOR ................................................................10-126
STRUCTURE OF NE (CRANKSHAFT) SPEED SENSOR ............................................................10-127
FUNCTION OF NE (CRANKSHAFT) SPEED SENSOR ...............................................................10-127
STRUCTURE OF Bkup (CAMSHAFT) SPEED SENSOR .............................................................10-128
FUNCTION OF Bkup (CAMSHAFT) SPEED SENSOR.................................................................10-128
STRUCTURE OF COMMON RAIL PRESSURE SENSOR ...........................................................10-129
FUNCTION OF COMMON RAIL PRESSURE SENSOR ...............................................................10-129
STRUCTURE OF EGR VALVE LIFT SENSOR .............................................................................10-130
FUNCTION OF EGR VALVE LIFT SENSOR.................................................................................10-130
STRUCTURE OF VGT SPEED SENSOR.....................................................................................10-131
FUNCTION OF VGT SPEED SENSOR ........................................................................................10-131
STRUCTURE OF VGT POSITION SENSOR ................................................................................10-132
FUNCTION OF VGT POSITION SENSOR ...................................................................................10-132
STRUCTURE OF MASS AIR FLOW AND TEMPERATURE SENSOR .........................................10-133
FUNCTION OF MASS AIR FLOW AND TEMPERATURE SENSOR.............................................10-133
STRUCTURE OF KDPF DIFFERENTIAL PRESSURE AND OUTLET PRESSURE SENSOR .....10-134
FUNCTION OF KDPF DIFFERENTIAL PRESSURE AND OUTLET PRESSURE SENSOR .........10-134
STRUCTURE OF CRANKCASE PRESSURE SENSOR...............................................................10-135
FUNCTION OF CRANKCASE PRESSURE SENSOR ..................................................................10-135
STRUCTURE OF AIR CLEANER CLOGGING SENSOR .............................................................10-136
FUNCTION OF AIR CLEANER CLOGGING SENSOR .................................................................10-136
STRUCTURE OF WATER-IN-FUEL SENSOR..............................................................................10-137
FUNCTION OF WATER-IN-FUEL SENSOR .................................................................................10-137
114E-6 SERIES 10-3

ABBREVIATION LIST 10 STRUCTURE AND FUNCTION
ABBREVIATION LIST
the meaning.
Abbrevia-
tion
component/system)
AISS Engine
System speed.
AJSS
Automatic Retarder
the downhill.
ASR
faces.
BCV
used.
Regulator
used independently.
Closed-center Load
Sensing System
10-4 114E-6 SERIES

10 STRUCTURE AND FUNCTION ABBREVIATION LIST

Abbrevia-
tion
component/system)
jector.
EGR Engine
emission of NOx.
tional Control
Structure
Forward-Neutral-Re-
verse
Communication
Plus)
Communication
Plus)
HSS
114E-6 SERIES 10-5


Abbrevia-
tion
component/system)
and communication.
Unit
trol motions.
IMA)
KCCV Engine
filters.

KCSF Engine
KDOC Engine
fler.
late Filter
assembled.
LIN
LVDS
MAF sensor.
10-6 114E-6 SERIES


Abbrevia-
tion
component/system)
Service
system
system
Open-center Load
Sensing System
load.
PCCS
pedals, and dials.
Hydraulic system
(D, PC, etc)
ROPS Cab and canopy
ISO 12117-2.
SCR Urea SCR system
devices.
114E-6 SERIES 10-7


Abbrevia-
tion
component/system)
Structure
tion of flow.
VGT Engine
VHPC Engine control
achieved.

D: Bulldozer
HD: Dump truck
WA: Wheel loader
A/C Air Conditioner
A/M Air Mix Damper
ACC Accessory
ADD Additional
AUX Auxiliary
BR Battery Relay
CW Clockwise
ENG Engine
F.G. Frame Ground
GND Ground
NC No Connection
10-8 114E-6 SERIES


S/T
Steering
STRG
SIG Signal
SOL Solenoid
STD Standard
OPT
Option
OP
PRESS Pressure
SPEC Specification
SW Switch
TEMP Temperature
T/M Transmission
114E-6 SERIES 10-9

LAYOUT DRAWING OF UREA SCR SYSTEM 10 STRUCTURE AND FUNCTION
UREA SCR SYSTEM

SCR
Abbreviation for Selective Catalytic Reduction
LAYOUT DRAWING OF UREA SCR SYSTEM

REMARK
The figure shows D65, Model 18 as an example.
1: Ammonia sensor 4: AdBlue/DEF tank heating valve

2: SCR outlet NOx sensor 5: AdBlue/DEF return hose
3: AdBlue/DEF injector 6: AdBlue/DEF tank sensor
10-10 114E-6 SERIES

10 STRUCTURE AND FUNCTION LAYOUT DRAWING OF UREA SCR SYSTEM
7: AdBlue/DEF suction hose 15: KDPF

8: AdBlue/DEF pressure hose 16: AdBlue/DEF mixing tube
9: SCR outlet temperature sensor 17: SCR temperature sensor
10: Ambient temperature sensor 18: SCR assembly
11: AdBlue/DEF pump 19: AdBlue/DEF injector coolant hose
12: AdBlue/DEF tank coolant inlet hose 20: AdBlue/DEF filler port
13: AdBlue/DEF tank breather 21: AdBlue/DEF tank
14: Turbocharger outlet NOx sensor 22: AdBlue/DEF tank coolant outlet hose
114E-6 SERIES 10-11

UREA SCR SYSTEM DIAGRAM 10 STRUCTURE AND FUNCTION
UREA SCR SYSTEM DIAGRAM
A: Coolant inlet B: Coolant outlet

1: Mass air flow and temperature sensor 21: KDPF temperature sensor controller
2: Engine 22: SCR temperature sensor
3: Engine controller 23: SCR outlet temperature sensor
4: KDPF assembly 24: SCR temperature sensor controller
5: KDOC unit 25: SCR outlet NOx sensor
6: KCSF unit 26: SCR outlet NOx sensor controller
7: KDPF differential pressure sensor 27: Smart sensor
8: KDPF outlet pressure sensor 28: Ambient temperature sensor
9: Turbocharger outlet NOx sensor 29: Engine room temperature sensor (*1)
10: Turbocharger outlet NOx sensor controller 30: AdBlue/DEF system
11: KDOC inlet temperature sensor 31: AdBlue/DEF tank heating valve
12: KDOC outlet temperature sensor 32: AdBlue/DEF tank
13: KDPF outlet temperature sensor 33: AdBlue/DEF tank sensor
14: KDPF temperature sensor controller 34: AdBlue/DEF suction line
15: AdBlue/DEF mixing tube 35: AdBlue/DEF return line
16: AdBlue/DEF injector 36: AdBlue/DEF pressure line
17: SCR assembly 37: AdBlue/DEF pump
18: Upstream SCR catalyst 38: AdBlue/DEF line heater relay
19: Downstream SCR catalyst and ammonia oxidation 39: Machine monitor
catalyst (integrated type)
20: Ammonia sensor
10-12 114E-6 SERIES

10 STRUCTURE AND FUNCTION UREA SCR SYSTEM DIAGRAM
*1: There are some machine models which are not equipped with it.
114E-6 SERIES 10-13

FUNCTION OF UREA SCR SYSTEM 10 STRUCTURE AND FUNCTION
FUNCTION OF UREA SCR SYSTEM
1: Engine 5: AdBlue/DEF injector

2: Engine controller 6: KDPF
3: AdBlue/DEF pump 7: SCR catalyst
4: AdBlue/DEF tank 8: Ammonia oxidation catalyst
• Urea SCR system is a device which converts toxic nitrogen oxides (NOx) in the exhaust gas into harmless
nitrogen and water.
• By spraying AdBlue/DEF into the exhaust gas, it decomposes and hydrolyzes to form ammonia (NH3) and
the ammonia selectively reacts with nitrogen oxides for the conversion to nitrogen and water.
FUNCTION OF AdBlue/DEF SUPPLY SYSTEM

1: AdBlue/DEF tank 5
2: AdBlue/DEF suction hose
6
3: AdBlue/DEF pump
4
3A: Flow control valve
3B: Pump
3C: AdBlue/DEF filter
3D: Pressure sensor 2
4: AdBlue/DEF return hose
1
5: AdBlue/DEF pressure hose
6: AdBlue/DEF injector 3A 3D
P
• AdBlue/DEF supply system consists of AdBlue/DEF tank
3C
(1), AdBlue/DEF hoses (2), (4), (5), AdBlue/DEF pump (3),
and AdBlue/DEF injector (6).
3B 3
• The AdBlue/DEF supply system is a part of the Komatsu
Urea SCR system and its function is to provide
AdBlue/DEF into the SCR Catalyst Assembly.
A4P15761
• However, the comprising devices, such as the AdBlue/DEF
pump, may not start functioning till certain conditions are
fulfilled.
• The AdBlue/DEF system has heating systems to thaw and prevent AdBlue/DEF from freezing because
AdBlue/DEF freezes at -11 °C.
10-14 114E-6 SERIES

10 STRUCTURE AND FUNCTION FUNCTION OF UREA SCR SYSTEM
Function of AdBlue/DEF injection system

• The AdBlue/DEF pump pressurizes AdBlue/DEF and delivers it into the AdBlue/DEF mixing tube through
the AdBlue/DEF injector.
• The amount of AdBlue/DEF injection is controlled by the Engine Controller.
• The amount of AdBlue/DEF injection is calculated based on the information of the turbocharger outlet NOx
sensor, the SCR catalyst temperature sensor, the SCR outlet temperature sensor, the ammonia sensor, the
SCR outlet NOx sensor and the exhaust gas flow rate.
• AdBlue/DEF injection is also controlled by the system temperature because Urea SCR systems are not ef-
fective in low temperature. For the monitoring of the system temperature, the KDPF outlet temperature sen-
sor is used in addition to the SCR temperature sensors.
• If any abnormality is detected in any of the sensors that are used for the calculation of the amount of AdBl-
ue/DEF injection and the monitoring of the system temperature, the Engine Controller commands termina-
tion of AdBlue/DEF injection. When this occurs, alerts will be activated and failure codes will be registered.
• Some abnormalities may cause large amount of urea precipitation inside the AdBlue/DEF mixing tube and
result in deposit of urea on the inner surfaces. If it continues and urea deposit accumulates AdBlue/DEF
injection can be blocked at the AdBlue/DEF injector or the exhaust gas flow can be choked in the passag-
es.
Function of purge system
• The AdBlue/DEF purging is incorporated to purge remain- 5
ing AdBlue/DEF in the AdBlue/DEF injector, AdBlue/DEF
hoses and the AdBlue/DEF pump to prevent AdBlue/DEF 6
from solidifying inside by precipitation or freezing. 4
• The AdBlue/DEF purging is activated automatically when
the engine is shut down or the ambient temperature falls
so low that the heating systems is not capable of maintain-
ing fluidity of AdBlue/DEF.
2
• In the case of the AdBlue/DEF purging of the engine shut-
down, the purging operation continues several minutes af-
1
ter the engine stops. Once the purging operation com-
pletes, the Engine Controller shuts itself down automatical- 3A 3D
ly. P
NOTICE
3C
Do not turn the battery disconnect switch to OFF position

3B 3
till the System Operating Lamp in the battery box goes out.
The System Operating Lamp will go out when the system
shuts itself down after the purging operation completes.
A4P15762
Function of heating system

• Thawing control system has the thawing mode and freeze prevention mode.
• Thawing mode is the function to thaw the frozen AdBlue/DEF.
• After starting engine, if the engine controller judges that AdBlue/DEF must be thawed, this function au-
tomatically heats the system.
• At this time, pressure control of AdBlue/DEF pump and injection of AdBlue/DEF are not performed until
the thawing is completed.
• Freeze prevention mode is the function to keep AdBlue/DEF warm to prevent it from freezing.
• This function automatically heats the system to prevent it from freezing while operating the machine, if
engine controller judges that AdBlue/DEF could be frozen.
• This function stops the pressure control of AdBlue/DEF pump and injection of AdBlue/DEF if it judges
that AdBlue/DEF is frozen while operating the machine.
114E-6 SERIES 10-15

• Thawing and freeze prevention are controlled by sensor, and the control sensors vary by devices which
AdBlue/DEF system consists of. The following table shows the relationship between the object devices of
thawing control, heating system, and control sensors for each mode.
Object devices of thawing control, heating system, and control sensors for each mode
When the engine room temperature sensor is equipped
Heating system Thawing mode Freeze prevention mode
AdBlue/DEF suction and purge
hose Ambient temperature Ambient temperature
Heater around hose
AdBlue/DEF pressure hose (low- sensor sensor
temperature side)
AdBlue/DEF pressure hose (high- Engine room temperature Engine room temperature
Heater around hose
temperature side) sensor sensor
AdBlue/DEF pump tem- Ambient temperature
AdBlue/DEF pump Pump built-in heater
perature sensor sensor
AdBlue/DEF tank temper- AdBlue/DEF tank temper-
AdBlue/DEF tank Circulation of coolant
ature sensor ature sensor
When the engine room temperature sensor is not equipped

Heating system Thawing mode Freeze prevention mode
AdBlue/DEF suction and purge
hose Ambient temperature Ambient temperature
Heater around hose
sensor sensor
AdBlue/DEF pressure hose
AdBlue/DEF pump tem- Ambient temperature
AdBlue/DEF pump Pump built-in heater
perature sensor sensor
AdBlue/DEF tank temper- AdBlue/DEF tank temper-
AdBlue/DEF tank Circulation of coolant
ature sensor ature sensor
10-16 114E-6 SERIES

INDUCEMENT STRATEGY
• The purpose of inducement is to prompt the operator to perform maintenance or repair on the emissions
control system.
• Inducement strategy is a control action to ensure prompt correction of various failures in the engine emis-
sions control system. It requires actions to limit engine performance and defines required indication such as
warning lamps and messages, as well as alarms while the control actions are imposed.
The warning steps of Inducement are different between for North America and for European Union.
• The categories of abnormalities that have triggered Inducement are displayed on the “SCR Information”
screen of the machine monitor.
INDUCEMENT STRATEGY WHEN THE AdBlue/DEF LEVEL IN THE TANK BE-

COMES LOW (FOR NORTH AMERICA)
• When the AdBlue/DEF level in the tank becomes low, AdBlue/DEF level caution lamp on the machine moni-
tor lights up, the Audible alert sounds, the action level is displayed and Inducement strategy including en-
gine power deration is activated.
• The Inducement strategy progresses in 5 levels from Warning, Escalated Warning, Mild Inducement, Se-
vere Inducement and Final Inducement.
• Up to the start of Severe Inducement the start of each warning step is triggered by the amount of
AdBlue/DEF in the AdBlue/DEF tank. Final Inducement starts at 1 hour after the start of Severe Inducement
if the machine continues its operation without adding AdBlue/DEF into the tank, and reduces the engine
speed to low idle and keeps it at low idle.
• The Inducement strategy status can be checked on “SCR Information” screen of the user menu.
• The table shows warning indications and engine power derations by each Inducement strategy status.
Machine monitor
AdBlue/DEF
level (*1) AdBlue/DEF Engine dera-
Status Message of level caution
(AdBlue/DEF Tone of audi- Activated fail- tion (*3)
SCR Informa- lamp
level gauge) ble alert ure code (*2)
tion
(Action level)
Red
10% CA3497
1: DEF low
1 Warning (The bottom level warning No sound (AdBlue/DEF No deration
two grada- appears. level low error
tions light on) 1)
5%
2: Without Red
(Within the CA3498
Escalated treatment, en- Triplet (*4)
2 Warning gradation of gine power (AdBlue/DEF No deration
Short intermit-
the second will be derat- level low error
(Warning 2) tently (*5)
from the bot- ed. 2)
tom )
Red
2.5%
Mild Induce- CA1673
ment (The grada- 3: Engine
Long intermit- (AdBlue/DEF Torque: over
3 tion of the end power is un-
(Inducement Red tently level low error 25%
of the bottom der deration.
1) 3)
lights on)
114E-6 SERIES 10-17

Machine monitor
AdBlue/DEF
SCR Informa- lamp
tion
(Action level)
Red
CA1673
Severe In- 0% 4: Engine Torque: 50%
ducement CA3547
(All grada- power is un-
4 Continuously (AdBlue/DEF and
(Inducement tions lights der heavy de- Red
2) off) ration. level low error RPM: 40%
4)
Red
Not remaining CA1673

Final Induce- in the tank CA3547
ment (*6) 5: Engine is Engine speed
5 running at low Continuously AS00ZK is fixed to low
(Inducement (All grada- idle. Red (AdBlue/DEF idle
3) tions lights level low error
off) 5)
*1: It is shown the value of Monitoring ID 19111: “AdBlue/DEF Level Corrected”.

*2: These failure codes are displayed on “Current Abnormality” in the operator mode, or “Abnormality Record” in
the service mode. For the failure codes, see TROUBLESHOOTING, “TROUBLESHOOTING POINTS FOR
UREA SCR SYSTEM”.
*3: These percentages show a torque reduction ratio from the full torque curve, and a speed reduction ratio from
the rated speed.
*4: Construction equipment with crawler
*5: Construction equipment with wheel
*6: After progressed “Severe Inducement” the status advances to “Final Inducement” with in 1 hour.
INDUCEMENT STRATEGY WHEN ABNORMALITY IS FOUND IN THE UREA SCR

SYSTEM DEVICES (FOR NORTH AMERICA)
• AdBlue/DEF system caution lamp lights up on machine monitor, and an action level is displayed when an
abnormality occurs in quality in AdBlue/DEF or in urea SCR system. In addition to the caution by the AdBl-
ue/DEF system caution lamp, alarm sounds as time passes after the abnormality occurred. Then, induce-
ment strategy starts so that the engine output is lowered.
• The Inducement strategy status and the categories of abnormalities can be checked on the “SCR Informa-
tion” screen of the machine monitor.
10-18 114E-6 SERIES

Machine monitor
Elapsed Caution Failure code Engine de-

Status Message of lamp Failure code
time (*1) Tone of au- for Induce- ration (*5)
SCR Infor- for abnormali-
mation (Action lev- dible alert ty (*2),(*3)
ment strategy
el) status (*4)
Yellow
1: Please
inspect and CA3571
1 Warning 1 hour maintain No sound No indication No deration
SCR sys- Yellow CB3571
tem.
Yellow
2: Without Triplet (*6) AS00R2

Escalated treatment,
2 Warning 2 hours engine Short inter- CA3571 (Warning 2 No deration
power will Yellow mittently CB3571 (SCR Device
(Warning 2)
be derated. (*7) Abnormality))
Red
AS00R3
Mild In- 3: Engine
ducement power is Long inter- CA3571 (Inducement Torque: over
3 3 hours 1(SCR De-
(Induce- under dera- Red mittently CB3571 25%
tion. vice Abnor-
ment 1)
mality))
Red
4: Engine AS00R4 Torque:

Severe In-
ducement power is CA3571 (Inducement 50%
Continu-
4 4 hours under 2 (SCR De-
(Induce- Red ously CB3571 and
heavy dera- vice Abnor-
ment 2) tion. RPM: 40%
mality))
114E-6 SERIES 10-19

Machine monitor

ment strategy
el) status (*4)
Red
AS00R5
Final In- Engine
ducement 5: Engine is CA3571 (Inducement
Until repair- Continu- speed is
5 running at 3 (SCR De-
(Induce- ing Red ously CB3571 fixed to low
low idle. vice Abnor-
ment 3) idle
mality))
*1: Elapsed time of each stage describes an accumulated time advancing to the next stage after starting “Warn-
ing”stage. Final Inducement is not cleared till abnormality is repaired.
the service mode. The failure code shown here is an example of failure code which is displayed on the machine
monitor when an abnormality occurs. For the failure codes, see TROUBLESHOOTING, “TROUBLESHOOTING
POINTS FOR UREA SCR SYSTEM”.
*3: The failure code which starts with CB may be displayed for the machine equipped with aftertreatment devi-
ces branching off to 2 lines.
the service mode.
the rated speed.
INDUCEMENT STRATEGY WHEN ABNORMALITY IS FOUND IN THE KDPF SYS-

TEM BY THE UREA SCR SYSTEM (FOR NORTH AMERICA)
• The Inducement strategy is different if Inducement is triggered by abnormalities in KDPF. It has 5 levels to-
tally which is the same as that, but it has different display on the machine monitor, and engine power dera-
tion (torque lowering ratio is 25% or more) and alarm starts from “Warning”.
10-20 114E-6 SERIES

Machine monitor

ment strategy
el) status (*4)
Red
1: Please
inspect and CA4151
Long inter- Torque: over
1 Warning 1 hour maintain No indication
Red mittently CB4151 25%
SCR sys-
tem.
Red
2: Without Yellow
Triplet (*6) AS00R2
Escalated treatment,
2 Warning 2 hours engine Short inter- CA4151 (Warning 2 Torque: over
power will mittently CB4151 (SCR Device 25%
(Warning 2)
Red
Red
Red AS00R3
Mild In- 3: Engine
ducement power is Long inter- CA4151 (Inducement Torque: over
3 3 hours 1 (SCR De-
(Induce- under dera- mittently CB4151 25%
tion. vice Abnor-
ment 1)
mality))
Red
114E-6 SERIES 10-21

Machine monitor

ment strategy
el) status (*4)
Red
4: Engine Red AS00R4 Torque:

Severe In-
Continu-
4 4 hours under 2 (SCR De-
(Induce- ously CB4151 and
heavy device Abnor-
ment 2) ration. RPM: 40%
mality))
Red
Red
Red AS00R5
Final In- Engine
ducement 5: Engine CA4151 (Inducement
Until repair- Continu- speed is
5 is running 3 (SCR De-
(Induce- ing ously CB4151 fixed to low
at low idle. vice Abnor-
ment 3) idle
mality))
Red
ing” stage. Final Inducement is not cleared till abnormality is repaired.
the service mode.
the rated speed.
10-22 114E-6 SERIES

FUNCTION OF TEMPORARY RESTORATION FROM INDUCEMENT (FOR NORTH

AMERICA)
• Temporary Restoration from Inducement is one of the Inducement strategies allowed to be included in Urea
SCR systems. In case the Urea SCR system advances to “Severe Inducement”, engine power is derated
heavily. This may cause difficulties of moving the machine to a safe place for adding AdBlue/DEF or trou-
bleshooting and correcting abnormalities of the Urea SCR system. For temporary remedies from these diffi-
culties the operator can restore engine power for a short time to the deration of “Mild Inducement” through
the machine monitor. Note that “Temporary Restoration from Inducement” does not regain full engine pow-
er.
• “Temporary Restoration from Inducement” can be activated only when the Urea SCR system is in “Severe
Inducement”. The maximum duration is limited to 30 minutes in each restoration operation, and 3 opera-
tions are allowed, but “Temporary Restoration from Inducement” is turned off whenever the system advan-
ces to “Final Inducement” even if either 30 minutes or 3 operations are not used up. All the abnormalities of
the Urea SCR system need to be corrected to regain another restoration capability.
• If all the abnormalities of the Urea SCR system are not corrected when the system is in “Severe Induce-
ment”, the system advances to “Final Inducement” in 1 hour after “Severe Inducement” started and engine
speed will be fixed to low idle to disable practical machine operation.
• To activate Temporary Restoration, follow the procedures described below.
REMARK
For the operating procedure on this function, refer to "TEMPORARY RESTORATION FROM INDUCE-
MENT" on the OPERATION section in the Operation and Maintenance Manual.
INDUCEMENT STRATEGY FOR ABNORMALITY RECURRENCE WITHIN 40

HOURS (FOR NORTH AMERICA)
• The Urea SCR system continuously monitors its operation conditions and stores information on inappropri-
ate operations including malfunctions.
• The stored information is utilized to monitor recurrences of abnormalities, “Abnormality Counter”. “Abnor-
mality Counter” is required by the authorities. The abnormality counting spans 40 hours and it monitors the
abnormalities that trigger Inducement other than the amount of AdBlue/DEF in the tank.
• If another abnormality/abnormalities is detected within 40 hours after the previous abnormalities were cor-
rected, regardless of the level of the previous Inducement and whether the new abnormality/abnormalities
is the same as the previous ones or not, it is judged as a recurrence.
• If a recurrence occurs, the Inducement strategy will be activated and starts from “Severe Inducement”.
• The duration of “Severe Inducement” in the recurrence is limited to 30 minutes. If the abnormalities are not
corrected while Inducement is in “Severe Inducement (30 minutes)”, Inducement will advance to “Final In-
ducement” and engine speed will be fixed to low idle to disable practical machine operation.
INDUCEMENT STRATEGY WHEN THE AdBlue/DEF LEVEL IN THE TANK BE-

COMES LOW (FOR EUROPEAN UNION)
• When the AdBlue/DEF level in the tank becomes low, AdBlue/DEF level caution lamp on the machine moni-
tor lights up, the Audible alert sounds, the action level is displayed and Inducement strategy including en-
gine power deration is activated.
• The Inducement strategy progresses in 4 levels from Warning, Continuous Warning, Low-Level Induce-
ment, and Severe Inducement.
• Up to the start of Severe Inducement the start of each warning step is triggered by the amount of
AdBlue/DEF in the AdBlue/DEF tank.
• The Inducement strategy status can be checked on “SCR Information” screen of the user menu.
114E-6 SERIES 10-23

Machine monitor
AdBlue/DEF
SCR Informa- lamp
tion
(Action level)
Red
10% CA3497
1: DEF low
1 Warning (The bottom level warning No sound (AdBlue/DEF No deration
two grada- appears. level low error
tions light on) 1)
5%
2: Without Red
(Within the CA3498
Continuous treatment, en- Triplet (*4)
2 Warning gradation of gine power (AdBlue/DEF No deration
Short intermit-
the second will be derat- level low error
(Warning 2) tently (*5)
from the bot- ed. 2)
tom )
Red
2.5%
Low-Level In- CA1673
ducement (The grada- 3: Engine
Long intermit- (AdBlue/DEF Torque: over
3 tion of the end power is un-
(Inducement Red tently level low error 25%
of the bottom der deration.
1) 3)
lights on)
Red
CA1673
Severe In- 0% 4: Engine Torque: 50%
ducement CA3547
(All grada- power is un-
4 Continuously (AdBlue/DEF and
(Inducement tions lights der heavy de- Red
2) off) ration. level low error RPM: 40%
4)
*1: It is shown the value of Monitoring ID 19111: “AdBlue/DEF Level Corrected”.

the service mode. For the failure codes, see TROUBLESHOOTING, “TROUBLESHOOTING POINTS FOR
UREA SCR SYSTEM”.
the rated speed.
INDUCEMENT STRATEGY WHEN ABNORMALITY IS FOUND IN THE AdBlue/DEF

QUALITY OR IN THE UREA SCR SYSTEM DEVICES (FOR EUROPEAN UNION)
• AdBlue/DEF system caution lamp lights up on machine monitor, and an action level is displayed when an
abnormality occurs in quality in AdBlue/DEF or in urea SCR system. In addition to the caution by the AdBl-
ue/DEF system caution lamp, alarm sounds as time passes after the abnormality occurred. Then, induce-
ment strategy starts so that the engine output is lowered.
10-24 114E-6 SERIES

• The Inducement strategy status and the categories of abnormalities can be checked on the “SCR Informa-
tion” screen of the machine monitor.
Machine monitor
AdBlue/DE
Elapsed F system Failure code Engine de-
Status Message of caution Failure code
SCR Infor- lamp for abnormali-
dible alert ment strategy
mation ty (*2),(*3)
(Action lev- status (*4)
el)
Yellow
1: Please
inspect and CA3571
1 Warning 5 hours maintain No sound No indication No deration
SCR sys- Yellow CB3571
tem.
Yellow
2: Without Triplet (*6) AS00R2

Continuous treatment,
2 Warning 10 hours engine Short inter- CA3571 (Warning 2 No deration
power will Yellow mittently CB3571 (SCR Device
(Warning 2)
Red
AS00R3
Low-Level 3: Engine
Inducement power is Long inter- CA3571 (Inducement Torque: over
(Induce- under dera- Red mittently CB3571 25%
tion. vice Abnor-
ment 1)
mality))
Red
4: Engine AS00R4 Torque:

Severe In-
Until repair- Continu-
4 under 2 (SCR De-
(Induce- ing Red ously CB3571 and
mality))
114E-6 SERIES 10-25

ing” stage. Final Inducement is not cleared till abnormality is repaired.
the service mode.
the rated speed.
INDUCEMENT STRATEGY WHEN ABNORMALITY IS FOUND IN THE KDPF SYS-

TEM BY THE UREA SCR SYSTEM DEVICES (FOR EUROPEAN UNION)
• The Inducement strategy is different if Inducement is triggered by abnormalities in KDPF. It has 4 levels to-
Machine monitor

ment strategy
el) status (*4)
Red
1: Please
inspect and CA4151
1 Warning 5 hours maintain No indication
SCR sys-
tem.
Red
2: Without Yellow
Triplet (*6) AS00R2
(Warning 2)
Red
10-26 114E-6 SERIES

Machine monitor

ment strategy
el) status (*4)
Red
Red AS00R3
Low-Level 3: Engine
tion. vice Abnor-
ment 1)
mality))
Red
Red

Severe In-
4 under 2 (SCR De-
(Induce- ing ously CB4151 and
mality))
Red
the service mode.
the rated speed.
114E-6 SERIES 10-27

INDUCEMENT STRATEGY WHEN ABNORMALITY IS FOUND IN THE EGR SYS-

TEM BY THE UREA SCR SYSTEM DEVICES (FOR EUROPEAN UNION)
• The Inducement strategy is different if Inducement is triggered by abnormalities in EGR. It has 4 levels to-
Machine monitor

ment strategy
el) status (*4)
Red
1: Please
inspect and CA2271
1 Warning 5 hours maintain No indication
SCR sys-
tem.
Red
2: Without Yellow
Triplet (*6) AS00R2
(Warning 2)
Red
Red
Red AS00R3
Low-Level 3: Engine
tion. vice Abnor-
ment 1)
mality))
Red
10-28 114E-6 SERIES

Machine monitor

ment strategy
el) status (*4)
Red

Severe In-
4 under 2 (SCR De-
(Induce- ing ously CB2271 and
mality))
Red
the service mode.
the rated speed.
FUNCTION OF TEMPORARY RESTORATION FROM INDUCEMENT (FOR EURO-

PEAN UNION)
• Temporary Restoration from Inducement is one of the Inducement strategies allowed to be included in Urea
SCR systems. In case the Urea SCR system advances to “Severe Inducement”, engine power is derated
heavily. This may cause difficulties of moving the machine to a safe place for adding AdBlue/DEF or trou-
bleshooting and correcting abnormalities of the Urea SCR system. For temporary remedies from these diffi-
culties the operator can restore engine power for a short time to the deration of “Low-Level Inducement”
through the machine monitor. Note that “Temporary Restoration from Inducement” does not regain full en-
gine power.
• “Temporary Restoration from Inducement” can be activated only when the Urea SCR system is in “Severe
Inducement”. The maximum duration is limited to 30 minutes in each restoration operation, and 3 opera-
tions are allowed. All the abnormalities of the Urea SCR system need to be corrected to regain another re-
storation capability.
• To activate Temporary Restoration, follow the procedures described below.
114E-6 SERIES 10-29

REMARK
For the operating procedure on this function, refer to "TEMPORARY RESTORATION FROM INDUCE-
MENT" on the OPERATION section in the Operation and Maintenance Manual.
INDUCEMENT STRATEGY FOR ABNORMALITY RECURRENCE WITHIN 40

HOURS (FOR EUROPEAN UNION)
• The Urea SCR system continuously monitors its operation conditions and stores information on inappropri-
ate operations including malfunctions.
• The stored information is utilized to monitor recurrences of abnormalities, “Abnormality Counter”. “Abnor-
mality Counter” is required by the authorities. The abnormality counting spans 40 hours and it monitors the
abnormalities that trigger Inducement other than the amount of AdBlue/DEF in the tank.
• If another abnormality/abnormalities is detected within 40 hours after the previous abnormalities were cor-
rected, regardless of the level of the previous Inducement and whether the new abnormality/abnormalities
is the same as the previous ones or not, it is judged as a recurrence.
• If a recurrence occurs, the Inducement strategy will be activated.
• Inducement in the recurrence resumes counting time at the time when the previous abnormalities were cor-
rected if the previous Inducement is in “Warning”, “Continuous Warning” or “Low-Level Inducement”. The
alerts resume the previous Inducement.
• If the time the previous abnormalities were corrected is in “Severe Inducement”, Inducement in the recur-
rence starts from “Low-Level Inducement” but the remaining time to “Severe Inducement” is 1 hour or 2
hours depending on abnormalities. If the 1 hour or 2 hours are used up without correcting the new abnor-
malities, Inducement will advance to “Severe Inducement” and engine power will be derated heavily.
10-30 114E-6 SERIES

10 STRUCTURE AND FUNCTION COMPONENT PARTS OF UREA SCR SYSTEM
COMPONENT PARTS OF UREA SCR SYSTEM

SCR
AdBlue/DEF MIXING TUBE

STRUCTURE OF AdBlue/DEF MIXING TUBE
REMARK
A: Exhaust gas inlet (from KDPF) B: Exhaust gas outlet (to SCR)
1: Clamp 4: AdBlue/DEF mixing tube (connector)
2: AdBlue/DEF injector 5: AdBlue/DEF mixing tube (tube)
3: Gasket for AdBlue/DEF injector
FUNCTION OF AdBlue/DEF MIXING TUBE

It mixes AdBlue/DEF injected from AdBlue/DEF injector with exhaust gas, and decomposes it to ammonia which
is needed to purge NOx from SCR assembly.
114E-6 SERIES 10-31

COMPONENT PARTS OF UREA SCR SYSTEM 10 STRUCTURE AND FUNCTION
SCR ASSEMBLY
SCR
STRUCTURE OF SCR ASSEMBLY

REMARK
10-32 114E-6 SERIES

A: From AdBlue/DEF mixing tube B: To exhaust pipe

1: SCR body 10: Sensor table
2: SCR temperature sensor 11: Sensor table band
3: SCR outlet NOx sensor 12: Catalyzer hold mat
4: SCR outlet temperature sensor 13: Water dam
5: Temperature sensor controller 14: Downstream SCR catalyst and ammonia oxidation
6: Ammonia sensor catalyst (integrated type)
7: Hanger plate 15: Upstream SCR catalyst
8: water baffle 16: Rectifier tube
9: Water drain port

• SCR assembly consists of rectifier tube (16) equalizing the distribution of flow speed by leading exhaust
gas, upstream SCR catalyst (15), downstream SCR catalyst, ammonia oxidation catalyst (14), and water
dam which prevents rain water from entering into downstream SCR catalyst and ammonia oxidation cata-
lyst (14) while exhausting gas.
• Ammonia oxidation catalyst (a part of 14) oxidizes ammonia to water and nitrogen with ammonia oxidation
catalyst (a part of 14) to prevent ammonia which is supplied to SCR assembly from being released out be-
cause SCR catalyst (a part of 14, 15)cannot completely consume it.
• Each 1 piece of SCR temperature sensor (2), SCR outlet temperature sensor (4), ammonia sensor (6), and
SCR outlet NOx sensor (3) are installed. These sensors are usable for various troubleshooting, such as
they are used to control the feedback of denitration efficiency or they monitor that SCR catalyst properly
functions or not.
• Rectifying tube (16) equalizes the distribution of exhaust gas flow speed.
• SCR catalyst (15, a part of 14) uses the ceramic honeycomb.
• The catalyzer holding mat (12) is made of a specific fiber and protects the ceramic catalyst against vibra-
tions by the engine and the machine body. It also protects the outer periphery of SCR assembly against a
heat transfer of the ceramics during operation.
• Water dam (13) is located at the upstream side of the outlet and prevents rainwater from entering into
downstream SCR catalyst unit and ammonia oxidation catalyst (14).
• Water baffle (8) is located at the downstream side of the outlet and prevents rainwater at outlet from splash-
ing over the detection part of NOx sensor.
114E-6 SERIES 10-33

AdBlue/DEF TANK
STRUCTURE OF AdBlue/DEF TANK
A: Coolant inlet D: From AdBlue/DEF pump

B: Coolant outlet E: To breather
C: To AdBlue/DEF pump
1: AdBlue/DEF tank sensor 5: AdBlue/DEF tank
2: Sensor flange assembly 6: AdBlue/DEF tank filter
3: Cap 7: Drain plug
4: Sight gauge
10-34 114E-6 SERIES

AdBlue/DEF TANK SENSOR

STRUCTURE OF AdBlue/DEF TANK SENSOR
REMARK
1: Connector 4: Level sensing part

2: Cover 5: Concentration Sensing part
3: Temperature sensing part
FUNCTION OF AdBlue/DEF TANK SENSOR

• This sensor is installed to AdBlue/DEF tank and outputs AdBlue/DEF level, AdBlue/DEF concentration, and
AdBlue/DEF temperature through CAN communication.
• AdBlue/DEF level and AdBlue/DEF concentration are measured by using ultrasonic wave.
• When the tank is frozen or empty, AdBlue/DEF level and AdBlue/DEF concentration are not measured.
114E-6 SERIES 10-35

AdBlue/DEF PUMP
STRUCTURE OF AdBlue/DEF PUMP
A: Suction from AdBlue/DEF tank
B: Return to AdBlue/DEF tank
C: Pressurized sending to AdBlue/DEF injector
1: AdBlue/DEF pump
2: AdBlue/DEF inlet connector
3: AdBlue/DEF return connector (*1)
4: AdBlue/DEF outlet connector
5: Electric connector
6: AdBlue/DEF filter cap
7: AdBlue/DEF filter (built-in)
*1: There are some machine models which are not equipped
with check valve.
• The followings are built-in: The filter to collect the dust in

AdBlue/DEF, the valve to switch the flow direction when
purging, and the heater to thaw AdBlue/DEF when it is fro-
zen.
• It sucks AdBlue/DEF from AdBlue/DEF tank, pressurizes it
to 900 kPa {9.18 kg/cm2} , and sends it to AdBlue/DEF in- 2 3 4
jector.
• To prevent wrong connection of connectors, the return
connectors are white and can be distinguished from oth-
ers. The sizes of inlet connector and outlet connector are
different and they cannot be connected each other.
P
A4P15769
10-36 114E-6 SERIES

AdBlue/DEF INJECTOR
STRUCTURE OF AdBlue/DEF INJECTOR
A: Pressurized sending from AdBlue/DEF pump
B: Coolant inlet
C: Coolant outlet
1: AdBlue/DEF injector
2: AdBlue/DEF inlet connector
3: Coolant inlet connector
4: Coolant outlet connector
5: Electric connector
FUNCTION OF AdBlue/DEF INJECTOR

• It injects AdBlue/DEF which is pressurized by AdBlue/DEF pump into AdBlue/DEF mixing tube.
• The injection amount is controlled by the valve opening or closing time while the pressure is constant.
• It circulates the engine coolant to prevent it from being heated by the heat from the exhaust pipe.
OPERATION OF AdBlue/DEF INJECTOR

Principle of injection of the injector is described. Following fig-
ure shows the state of injection.
1. Engine controller sends the electrical signal to control
AdBlue/DEF injector.
2. Solenoid (4) moves seal ball (2), and seal ball (2) leaves
from injection port (1) to make opening state.
Pressurized AdBlue/DEF by AdBlue/DEF pump is injected.
3. When the electrical signal is not sent, seal ball (2) closes
injection port (1) with spring force (3), so AdBlue/DEF is
not injected.
114E-6 SERIES 10-37

AdBlue/DEF HOSE
STRUCTURE OF AdBlue/DEF HOSE
1: Connector 5: Insulation tape

2: Housing 6: Heating wire
3: Coupling 7: Nylon tube
4: Corrugated tube
• It is used as AdBlue/DEF piping between AdBlue/DEF tank and AdBlue/DEF pump or between AdBlue/DEF
pump and AdBlue/DEF injector.
• The shape of the engaging portion between AdBlue/DEF tank and AdBlue/DEF pump or AdBlue/DEF injec-
tor pin is based on 3/8 inches or 5/16 inches of SAE J2044. It can be disconnected or connected with one
touch.
• There are 2 types of hose end shape such as straight shape and 90 deg. elbow shape.
• There are 2 types of nylon tubes of its outside diameter 5 mm and 8 mm. Choose the suitable one accord-
ing to the model and the part to use.
FUNCTION OF AdBlue/DEF HOSE

• In the cold weather, the specified current flows in the heating wire immediately after the engine is started. It
heats nylon tube and thaws AdBlue/DEF which has frozen in the nylon tube.
• It also keeps temperature constant to prevent AdBlue/DEF from freezing again while machine is operated.
10-38 114E-6 SERIES

AdBlue/DEF TANK HEATING VALVE

STRUCTURE OF AdBlue/DEF TANK HEATING VALVE
A: Engine coolant inlet B: Engine coolant outlet

1: Solenoid 5: Plunger
2: Solenoid core 6: Diaphragm
3: Solenoid coil 7: Valve
4: Spring
FUNCTION OF AdBlue/DEF TANK HEATING VALVE

• AdBlue/DEF tank heating valve thaws AdBlue/DEF tank, and opening/closing of the valve (7) is done by
solenoid (1).
• The opening position of valve is fixed and the control is only for opening/closing. When the solenoid (1) is
de-energized, the valve is closed.
• Diaphragm (6) prevents entering of engine coolant into solenoid (1).
OPERATION OF AdBlue/DEF TANK HEATING VALVE

1. When solenoid coil (3) is energized, solenoid core (2) is magnetized and pull plunger (5) to open valve (7)
which is directly connected to plunger (5).
2. When solenoid coil (3) is de-energized, solenoid core (2) loses pulling force and plunger (5) is pushed down
by spring (4) and valve (7) is closed.
114E-6 SERIES 10-39

LAYOUT OF ENGINE COMPONENTS 10 STRUCTURE AND FUNCTION
ENGINE SYSTEM
LAYOUT OF ENGINE COMPONENTS
LAYOUT DRAWING OF ENGINE COMPONENTS
REMARK
Sectional view
1: SCR assembly 3: KDPF

2: AdBlue/DEF mixing tube 4: Air cleaner
10-40 114E-6 SERIES

10 STRUCTURE AND FUNCTION LAYOUT OF ENGINE COMPONENTS
5: KCCV 11: VGT

6: Engine controller 12: Alternator
7: Supply pump 13: EGR cooler
8: Engine boost oil pump 14: Engine oil filter
9: Vibration damper 15: Engine oil pan
10: Auto-tensioner 16: Starting motor
114E-6 SERIES 10-41

INTAKE AND EXHAUST SYSTEM PARTS 10 STRUCTURE AND FUNCTION
INTAKE AND EXHAUST SYSTEM PARTS

LAYOUT DRAWING OF INTAKE AND EXHAUST SYSTEM
REMARK
A: KDPF E: From air cleaner

B: From EGR valve F: To aftercooler
C: From aftercooler G: From exhaust manifold
D: To intake manifold
1: VGT 4: Exhaust manifold
2: EGR valve 5: EGR cooler
3: Intake connector
10-42 114E-6 SERIES

10 STRUCTURE AND FUNCTION INTAKE AND EXHAUST SYSTEM PARTS
INTAKE AND EXHAUST SYSTEM CIRCUIT DIAGRAM
A: From atmosphere B: To atmosphere

1: Air cleaner 9: KDPF
2: VGT 10: EGR cooler
3: Air-cooled aftercooler 11: Flywheel housing
4: Intake air heater 12: Engine oil pan
5: Intake manifold 13: Engine
6: Exhaust manifold 14: Mixing connector
7: EGR valve 15: AdBlue/DEF mixing tube
8: KCCV ventilator 16: SCR assembly
FUNCTION OF INTAKE AND EXHAUST SYSTEM

• This engine is equipped with VGT (Variable Geometry Turbocharger), EGR system (EGR valve, EGR cool-
er) which recirculate a part of exhaust gas to the combustion chamber to reduce generation of NOx, KDPF
(KOMATSU Diesel Particulate Filter) which is an exhaust gas purifying device, and KCCV (KOMATSU
Closed Crankcase Ventilation) which recirculate the blowby gas.
• Since clean air is required to maintain the engine performance, the engine is damaged and its performance
is degraded, if it takes dirt or dust into it.
• Air is sucked into the engine through air cleaner (1), VGT (2), and air-cooled aftercooler (3).
Also, since VGT is equipped with the variable mechanism which is not installed to conventional turbocharg-
er, foreign material can damage VGT largely. Accordingly, cleaner or replace the air cleaner element ac-
cording to the procedure in Operation and Maintenance Manual, and take extreme care that foreign materi-
al does not enter.
• The intake air is sucked into the compressor side of VGT (2) through air cleaner (1). The air turbocharged
by VGT (2) is cooled by air-cooled aftercooler (3). Then, the air flows through mixing connector (14) and
intake manifold (5) into the cylinders and is used for combustion.
114E-6 SERIES 10-43

• The exhaust gas flows through exhaust manifold (6) to the turbine of VGT (2) and drives the turbine wheel
with its energy.
• To attain both clean exhaust gas and low fuel consumption, EGR system outputs signals from the engine
controller so that EGR valve (7) opens properly according to the engine load.
• When EGR valve (7) opens, a part of the exhaust gas (EGR gas) flows through exhaust manifold (6) and
EGR piping to EGR cooler.
• The exhaust gas cooled by EGR cooler (10) flows through EGR valve (7) and mixes with the intake air in
mixing connector (14), and then flows in intake manifold (5).
• KDPF (9) is installed to conform with the exhaust gas regulations and composed of KDOC (oxidation cata-
lyst) and KCSF (soot collecting filter).
• KDPF collects particulate soot contained in the exhaust gas of the engine to clean the exhaust gas.
• AdBlue/DEF mixing tube (15) mixes AdBlue/DEF injected by AdBlue/DEF injector with the exhaust gas to
hydrolyze the exhaust gas into ammonia at high temperature.(*1)
• SCR assembly (16) makes the ammonia decomposed in AdBlue/DEF mixing tube (15) react chemically
with toxic nitrogen oxides (NOx) contained in the exhaust gas in the catalyst, and decomposes them into
harmless nitrogen and water.(*1)
10-44 114E-6 SERIES

10 STRUCTURE AND FUNCTION INTAKE AND EXHAUST SYSTEM PARTS
AIR CLEANER
STRUCTURE OF AIR CLEANER
REMARK
General view and sectional view
1: Vacuator valve 5: Mass air flow and temperature sensor mounting

2: Inlet portion
3: Air cleaner clogging sensor or dust indicator mount- 6: Rectifying wire net
ing portion 7: Outer element
4: Outlet 8: Inner element
SPECIFICATIONS OF AIR CLEANER

Type: Cyclopac type
Filtering area (outer cylinder): 9.94 m2
Filtering area (inner cylinder): 1.33 m2
OPERATION OF AIR CLEANER

1. Since inlet (2) is placed in the tangential direction, the intake air swirls along the body and generates a cen-
trifugal force.
2. The dust in the intake air is separated by the centrifugal separation effect.
3. Outer element (7) removes dust 99.9 % or more, and only clean air passes through inner element (8) and
rectifying wire net (6), and is sucked into engine through outlet (4).
4. Rectifying wire net (6) rectifies the intake air flow and the air flow to the temperature sensor which have
large effects on control of the engine.
5. The dust removed during the air intake process is automatically discharged out through vacuator valve (1)
when the engine stops.
114E-6 SERIES 10-45

INTAKE AIR HEATER

STRUCTURE OF INTAKE AIR HEATER
1: Heater coil 3: Internal wiring diagram

2: Housing
SPECIFICATIONS OF INTAKE AIR HEATER

Type of heater: Ribbon heater
Rated voltage : 22 V (DC)
Load current : 100 A
10-46 114E-6 SERIES

10 STRUCTURE AND FUNCTION ENGINE MAIN BODY PARTS
ENGINE MAIN BODY PARTS

CYLINDER HEAD
STRUCTURE OF CYLINDER HEAD
REMARK
1: Cylinder head 3: Cylinder head bolt

2: Cylinder head cover 4: Injector assembly
SPECIFICATIONS OF CYLINDER HEAD

Cylinder head
Direct fuel injection type
Integrated type
114E-6 SERIES 10-47

ENGINE MAIN BODY PARTS 10 STRUCTURE AND FUNCTION
4-valve
Valve seat
Press-fitted valve seat inserts on both intake and exhaust sides
Injector assembly
Installation: Dry type (without sleeve)
10-48 114E-6 SERIES

CYLINDER BLOCK
STRUCTURE OF CYLINDER BLOCK
REMARK
1: Main bearing cap 3: Cylinder block

2: Main bearing cap bolt 4: Cam bushing
SPECIFICATIONS OF CYLINDER BLOCK

Cylinder block
Crankshaft portion: 7 bearings
Camshaft portion: 7 bearings
114E-6 SERIES 10-49

Cylinder liner
Wet type
Machining of inside surface: Plateau honing
10-50 114E-6 SERIES

MAIN MOVING PARTS

STRUCTURE OF MAIN MOVING PARTS
REMARK
Structural view
1: Crankshaft gear 3: Connecting rod

2: Crankshaft 4: Piston
114E-6 SERIES 10-51

Piston
1: Piston 4: Oil ring

2: Top ring 5: Piston pin
3: Second ring
Connecting rod
General view
1: Connecting rod bushing 4: Connecting rod cap

2: Connecting rod 5: Connecting rod bolt
3: Connecting rod bearing
SPECIFICATIONS OF MAIN MOVING PARTS

Crankshaft
Closed die forging
Journal: Induction hardening
10-52 114E-6 SERIES

Piston
Toroidal combustion chamber for direct fuel injection
Aluminum piston (shaker)
Connecting rod
Closed die forging
Cap bolt: Screwed-in type (torque plus angle method tightening)
PISTON RING
STRUCTURE OF PISTON RING
Sectional view
1: Top ring
2: Second ring
3: Oil ring
Structure
Top ring (1) is a keystone, inner cut, barrel face, hard chromium plated ring.
Second ring (2) is tapered and hard chromium plated.
Oil ring (3) is an M-shaped steal ring equipped with a coil expander and hard chromium plated.
114E-6 SERIES 10-53

VIBRATION DAMPER
STRUCTURE OF VIBRATION DAMPER
REMARK
General view
1: Vibration damper 3: Vibration damper bolt

2: Crankshaft pulley
FUNCTION OF VIBRATION DAMPER

Vibration damper (1) absorbs torsional vibration acting on the crankshaft and prevents breakage of the crank-
shaft and abnormal wear of the shaft and gears.
10-54 114E-6 SERIES

TIMING GEAR
STRUCTURE OF TIMING GEAR
REMARK
General view
1: Oil pump gear (number of teeth: 24) 4: Cam gear (number of teeth: 84)
2: PTO idler gear (number of teeth: 23) 5: Fuel supply pump (number of teeth: 84)
3: Crank gear (number teeth: 42)
114E-6 SERIES 10-55

FRONT COVER
STRUCTURE OF FRONT COVER
REMARK
General view
1: Front gear cover 4: Front seal cover

2: Front gear housing 5: Front seal
3: Gasket
10-56 114E-6 SERIES

VALVE SYSTEM
STRUCTURE OF VALVE SYSTEM
1: Cam gear (number of teeth: 84) 8: Valve cotter

2: Thrust plate 9: Adjustment screw
3: Camshaft 10: Lock nut
4: Intake valve 11: Rocker arm
5: Exhaust valve 12: Push rod
6: Valve spring 13: Tappet
7: Valve stem seat
114E-6 SERIES 10-57

FLYWHEEL AND FLYWHEEL HOUSING

STRUCTURE OF FLYWHEEL AND FLYWHEEL HOUSING
REMARK
1: Flywheel housing 4: Flywheel

2: Starting motor 5: Rear seal
3: Ring gear (number of teeth: 148)
SPECIFICATIONS OF FLYWHEEL AND FLYWHEEL HOUSING

For wet type: Double lip
10-58 114E-6 SERIES

10 STRUCTURE AND FUNCTION TURBOCHARGER SYSTEM
TURBOCHARGER SYSTEM
CIRCUIT DIAGRAM OF VGT SYSTEM
C: Blower impeller T: Turbine impeller

1: Air Cleaner 7: Engine controller
2: Mass air flow and temperature sensor 8: EPC valve (for VGT)
3: VGT 9: KDPF
4: VGT speed sensor 10: SCR assembly(*1)
5: VGT position sensor 11: EGR system (EGR cooler, EGR valve)
6: Hydraulic actuator 12: EGR valve lift sensor
114E-6 SERIES 10-59

TURBOCHARGER SYSTEM 10 STRUCTURE AND FUNCTION
FUNCTION OF VGT SYSTEM

VGT Control System

1: Air cleaner 7: Engine controller
2: Mass air flow and temperature sensor 8: EPC valve (for VGT)
3: VGT 9: KDPF, AdBlue/DEF mixing tube, SCR assembly
4: VGT speed sensor 10: EGR system (EGR cooler, EGR valve)
5: VGT position sensor 11: EGR valve lift sensor
6: Hydraulic actuator
• Engine controller (7) processes the data of VGT position sensor (5), intake air flow and temperature sensor
(2), VGT speed sensor, etc. and sends the result to hydraulic actuator (6) via oil pressure controlled by EPC
valve to move the piston.
• High altitude is recognized by the ambient pressure sensor, and the fuel injection and VGT are controlled
automatically to secure better response at high altitude.
• The rotation of VGT is controlled to protect VGT from overspeed.
Lubrication
• The lubricating oil cooled by the engine oil cooler is supplied through the feed pipe to VGT.
• The oil is sent to the bearing housing to lubricate the shaft bearing and thrust bearing.
• The return oil flows through the return pipe connected to under the bearing housing and falls into the engine
oil pan.
Cooling
• The coolant from the cylinder block flows into the center housing to cool VGT.
• The return coolant flows from the center housing to the water pump inlet.
10-60 114E-6 SERIES

VGT
VGT
Abbreviation for Variable Geometry Turbocharger
STRUCTURE OF VGT
REMARK
General view, sectional view
A: Intake air inlet C: Exhaust inlet

B: Intake air outlet D: Exhaust outlet
114E-6 SERIES 10-61

1: Blower housing 7: Nozzle ring

2: VGT speed sensor 8: Push rod
3: Hydraulic actuator 9: Shaft
4: Turbine housing 10: Blower impeller
5: Plate 11: Turbine impeller
6: Vane 12: Piston
FUNCTION OF VGT

1: Air cleaner 5: SCR assembly(*1)
2: VGT 6: EGR cooler
3: KDPF 7: EGR valve
4: AdBlue/DEF mixing tube(*1)
• The exhaust gas regulations are applied to the exhaust gas from the engine running at low speed, as well
as at high speed. To meet this, the EGR ratio is improved. (EGR ratio = Ratio of amount of EGR to amount
of fresh suction air)
• To attain high EGR ratio, turbine inlet pressure (P3) must be set higher than boost pressure (P2) (P3 > P2).
For this reason, the variable turbocharger (VGT) is employed, in which the exhaust gas pressure acting on
turbine impeller (T) is adjustable.
Also, since the boost pressure increases more quickly, generation of particulate caused by lack of oxygen
during low-speed operation (rotation) is reduced.
• The shaft joined to turbine impeller (T) drives blower impeller (C) and sends much air to the cylinder for
combustion.
If VGT (2) sends more air, the fuel injection rate can be increased, thus the engine output is increased.
In addition, the air cooled by aftercooler becomes dense, that is, more oxygen is supplied, thus the fuel in-
jection rate can be increased and the engine output is increased.
NOTICE
Adequate amount of clean high quality oil is required to maintain VGT performance. Be sure to use Ko-
matsu genuine high quality oil. Follow the procedures in the Operation and Maintenance Manual when
replacing oil or oil filter.
REMARK
It sounds like air is leaking from VGT or a boost pipe, but it is not abnormal.
10-62 114E-6 SERIES

OPERATION OF VGT
1. The exhaust gas enters (C) of turbine housing (4) and flows out through portion (P) and (D). Portion (P) is
surrounded by plate (5) fixed to turbine housing, nozzle ring (7), and vanes (6).
The area of its passage is changed by sliding push rod (8) to the right or left.
2. Hydraulic actuator (3) moves piston (12) in the actuator up and down with the hydraulic pressure controlled
by EPC valve installed to the EGR valve, and slides push rod (8) to the right and left.
3. The exhaust gas flowing through vanes (6) rotates blower impeller (10) through shaft (9) joined to turbine
impeller (11). As the result, the blower impeller works as a compressor, and the intake air entering through
(A) is compressed and discharge through (B).
4. When the exhaust gas pressure at inlet (C) of turbine housing (4) is low (engine speed is in low range),
push rod (8) slides to the right and narrows portion (P).
5. The exhaust gas acting on turbine impeller (11) increases, the turbocharger speed increases, and more air
(oxygen) is taken in.
VGT speed sensor (2) senses the rotation of the turbocharger.
When nozzle ring is "closed"
1. During low speed operation (rotation), exhaust gas inlet
passage (P) is narrow (L1). (It is not fully closed, however.)
2. If the turbine inlet pressure increases while the nozzle ring
is closed, the turbine inflow speed increases, and accord-
ingly the turbocharger speed increases.
114E-6 SERIES 10-63

When nozzle ring is "open"

1. During high speed operation (rotation), exhaust gas inlet
passage (P) is wide (L2).
2. As the engine speed increases and the turbine inlet pres-
sure (exhaust gas pressure) increases exhaust gas inlet
passage (P) is widened (L2) so that the exhaust gas acts
on turbine impeller (11) efficiently.
REMARK
• Nozzle ring (7), vanes (6), and push rod (8) are made in
one unit, and push rod (8) slides only and does not rotate.
• Hydraulic actuator (3) is equipped with VGT position sen-
sor. VGT position sensor is calibrated together with the vari-
able mechanism of VGT and the result is written in the
memory in VGT position sensor. Accordingly, if any of hy-
draulic actuator (3), VGT position sensor, and VGT unit
fails, whole VGT must be replaced.
Operation of hydraulic actuator
REMARK
1. Hydraulic actuator (1) is controlled by EPC valve (3) instal-
led to EGR valve (2) and driven hydraulically.
2. The hydraulic pressure supplied by boost oil pump (4) is
used for this purpose.
3. The position of hydraulic actuator (1) is fed back to engine
controller by the signals from VGT position sensor.
10-64 114E-6 SERIES

EGR SYSTEM
EGR
Abbreviation for Exhaust Gas Recirculation
LAYOUT DRAWING OF EGR SYSTEM

REMARK
1: VGT 4: Intake connector

2: EGR valve 5: Exhaust manifold
3: Intake pipe 6: EGR cooler
FUNCTION OF EGR SYSTEM

• EGR valve (hydraulically driven type) (2) controls the gas flowing from the exhaust section to the intake
section.
Since the exhaust pressure is higher than the boost pressure, the exhaust gas flows to the intake side.
• EGR cooler (6) cools down the exhaust gas.
Engine coolant is used for cooling.
• It controls EGR circuit on the basis of the information from the sensors installed to various parts so that
clean exhaust gas is always discharged to obtain EGR ratio corresponding to the operating condition. (EGR
ratio means the ratio of EGR gas contained in the intake gas.)
114E-6 SERIES 10-65

• It monitors EGR circuit for troubleshooting with sensor installed to each part to prevent a serious failure
from occurring.
CIRCUIT DIAGRAM OF EGR SYSTEM

1: Air Cleaner 9: EGR valve lift sensor
2: KDPF, AdBlue/DEF mixing tube, SCR assembly 10: EPC valve (for VGT)
3: Ambient pressure sensor 11: Exhaust manifold
4: Aftercooler 12: Engine boost oil pump
5: EGR cooler 13: Intake manifold
6: EGR valve 14: Charge (boost) pressure and temperature sensor
7: Hydraulic actuator (power piston) 15: Engine controller
8: EPC valve (for EGR valve) 16: Mass air flow and temperature sensor
OPERATION OF EGR SYSTEM

1. The engine controller outputs signals in order to open EGR valve (6) most properly in accordance with the
engine load, so that both of the clean exhausting gas and low fuel consumption can be achieved.
2. When EGR valve (6) opens, a part of the exhaust gas (EGR gas) flows from exhaust manifold (11) into
EGR cooler (5) through the EGR piping.
3. The exhaust gas cooled by EGR cooler (5) flows through EGR valve (6) and mixes with the intake air in the
intake connector, and then flows in intake manifold (13).
10-66 114E-6 SERIES

EGR VALVE
EGR
STRUCTURE OF EGR VALVE

REMARK
Sectional view
A: EGR gas inlet (from EGR cooler) D: Servo drive oil outlet
B: EGR gas outlet (to intake manifold) E: VGT control hydraulic outlet
C: Servo drive oil inlet F: VGT drive pressure outlet
1: Valve 5: Spring
2: Spring 6: EGR valve lift sensor
3: Power piston 7: EPC valve (for EGR)
4: Spool 8: EPC valve (for VGT)
Structure
• EGR valve consists of the EGR gas flow control mechanism and EPC valve.
• There are 2 EPC valves, one for the EGR valve and the other for VGT.
114E-6 SERIES 10-67

OPERATION OF EGR VALVE

1. The oil from the engine boost oil pump flows in port (C) of
EGR valve. The control pressure from EPC valve solenoid
enters port (E).
2. Spool (4) is moved to the right by the reaction force of
spring (5), and valve (1) is closed by the reaction for spring
(2). Accordingly, the exhaust gas from EGR cooler does
not flow to the intake side.
3. To open valve (1), the control pressure from EPC valve en-
ters port (E) first. The position of spool (4) is determined by
the balance of the control pressure and spring (5).
4. Since the notch of power piston (3) opens, the oil from the
engine boost oil pump flows through port (C) and pushes
power piston (3) to the left.
5. The oil from the engine boost oil pump acts on power piston (3) and generates force (Fp).
6. When force (Fp) increases more than reaction force (Fs) of spring (2), EGR valve (1) opens and the ex-
haust gas flows to the intake side.
7. Reaction force (Fs) of spring (2) and force (Fp) of power piston are balanced since the engine controller
controls the control pressure with EPC valve solenoid.
8. Since the servo mechanism is applied, external force applied to valve (1) does not act on spool (4) which is
in contact with power piston (3).
9. EGR valve lift sensor senses the displacement of spool (4).
10-68 114E-6 SERIES

EGR COOLER
EGR
STRUCTURE OF EGR COOLER

REMARK
A: EGR gas inlet D: EGR gas outlet (to EGR valve)

B: Air vent E: Coolant inlet
C: Coolant outlet
1: Flat tube
Detailed drawing of flat tube
1: Flat tube
2: Inner fin
OPERATION OF EGR COOLER

• EGR gas enters through (A) and flows through flat tubes (1) (11 pieces).
114E-6 SERIES 10-69

• Coolant enters through (E), flows outside of flat tubes (1) in the case, and goes out through (C).
• Flat tube (1) has inner fins (2), thus EGR gas is cooled efficiently and discharged through EGR gas outlet
(D).
10-70 114E-6 SERIES

KCCV SYSTEM
KCCV
Abbreviation for KOMATSU Closed Crankcase Ventilation
LAYOUT DRAWING OF KCCV SYSTEM

REMARK
A: Blowby gas C: Removed engine oil (to engine oil pan)

B: Blowby gas from which engine oil is removed (to
VGT)
1: KCCV ventilator 3: VGT
2: CDR valve 4: Check valve
FUNCTION OF KCCV SYSTEM

• In the past, blowby gas (A) was allowed to be released into the atmosphere in the past, but now it is re-
stricted by emission regulations.
• Blowby gas (A) contains ingredients of the engine oil. A filter is installed to KCCV ventilator (1) to remove
the engine oil to prevent the following possible problems if it is recirculated to VGT (3) as it is.
• Deterioration of turbocharger and aftercooler performance caused by sticking engine oil
114E-6 SERIES 10-71

• Abnormal combustion in engine

• Malfunction of each sensor caused by sticking engine oil
FORMING OF CONDENSED WATER AND EMULSION IN KCCV SYSTEM
A: Inside of KCCV piping C: Back of head cover

B: inside of breather D: Dipstick
1: Air Cleaner 5: Breather
2: VGT 6: KCCV ventilator
3: Aftercooler 7: Engine oil pan
4: Engine
10-72 114E-6 SERIES

Outline of forming of condensed water and emulsion in KCCV system

• If low-load operation is continued while the ambient tem-
perature is low, moisture in the blowby gas does not evap-
orate but condenses, and is returned to engine oil pan (7)
through KCCV ventilator (6).
The flow of this phenomenon is as follows;
1. Moisture in blowby gas condenses in KCCV piping
(A).
2. The condensed water flows into engine oil pan (7)
through the drain circuit.
3. The water evaporates in engine oil pan (7).
4. When the water vapor condenses again inside the en-
gine where the temperature is relatively low, it is
mixed with oil and clouded sediment is produced.
This sediment is called mayonnaise sludge (*1).
5. If the temperature of various parts does not increase
because of light-load operation, mayonnaise sludge
(*1) is accumulated.
• Mayonnaise sludge (*1) is produced inside breather (B),
on back of head cover (C), dipstick (D), etc. where the
temperature is low and condensation occurs easily.
• Mayonnaise sludge (*1) is eliminated when loaded opera-
tion is continued and the engine oil temperature increases.
• Mixing of water condensed from the blowby gas into the oil
is not problem. However, if the engine coolant is mixed in,
the cause of coolant leakage must be removed.
*1: Emulsion made from oil and water which looks like mayon-
naise
114E-6 SERIES 10-73

OPERATION OF KCCV SYSTEM

Drawing on the left shows the conventional flow of blowby gas. Drawing on the right shows the flow of blowby
gas which is sucked in KCCV ventilator and recirculated.
A: Blowby gas C: Engine oil

B: Clean gas
1: Air cleaner 5: Breather
2: Turbocharger 6: KCCV ventilator
3: Aftercooler 7: Engine oil pan
4: Cylinder block (crankcase) 8: VGT
1. This system removes engine oil (C) from blowby gas (A) in cylinder block (4) by using the filter in KCCV
ventilator (6), and recirculate clean gas (B) to the air intake side of VGT (8).
2. Separated engine oil (C) is drained to engine oil pan (7) through the check valve.
10-74 114E-6 SERIES

KCCV VENTILATOR
KCCV
Abbreviation for KOMATSU Closed Crankcase Ventilation
STRUCTURE OF KCCV VENTILATOR

REMARK
A: Blowby gas inlet (from engine breather) C: Oil drain port (to engine oil pan)
B: Blowby gas outlet (to VGT intake side)
1: Case 4: Relief valve
2: CDR valve 5: Impactor
3: Crankcase pressure sensor 6: Filter
Structure
• Filter (6) is classified by the working direction for filter replacement into the top load type (removed upward)
and bottom load type (removed downward).
• The top load type (removed upward) and bottom load type (removed downward) are different from each
other in the position of the crankcase pressure sensor.
In the top load type (removed upward), the crankcase pressure sensor is installed to the bottom of KCCV
ventilator.
In the bottom load type (removed downward), the crankcase pressure sensor is installed to the top of
KCCV ventilator.
FUNCTION OF KCCV VENTILATOR

• If the blowby gas is returned to the intake side of VGT and crankcase pressure becomes negative, the dust
may be sucked in through crank seal.
114E-6 SERIES 10-75

The pressure inside the crankcase is controlled by CDR valve (2) to prevent this to occur.
• Crankcase pressure may increase and oil leakage may occur if filter (6) of KCCV ventilator is clogged.
Thus, crankcase pressure sensor detects the clogging of filter (6).
• Relief valve (4) is inside case (1), and it operates to bypass the blowby gas and protect both KCCV ventila-
tor and the engine when filter (6) is blocked.
OPERATION OF KCCV VENTILATOR

1. When the blowby gas enters blowby gas inlet (A) and passes through the hole of impactor (5) in filter (6),
large particles in the oil mist are separated.
2. Small particles in the oil mist are separated by filter (6).
3. The separated oil oozes out from the bottom of the filter (6), and flows to oil drain port (C), and then flows to
the engine oil pan.
4. The crankcase pressure sensor senses the crankcase pressure (blowby gas pressure).
If the engine controller judges through detected value of crankcase pressure sensor that the filter is clog-
ged, it displays failure code CA555, and if the pressure increases further, it displays failure code CA556.
5. Relief valve (4) is installed in case (1) and operates when filter (6) is blocked.
6. When the crankcase pressure becomes negative, CDR valve (2) operates for it not to become excessively
negative.
CDR VALVE
CDR
Abbreviation for Crankcase Depression Regulator
OPERATION OF CDR VALVE

1. Spring (2) normally pushes up diaphragm (1), and the
blowby gas flows from crankcase side (A) into turbocharg-
er side (air intake side) (B).
2. As the intake air at turbochaeger side (air intake side) (B)
increases, pressure on crankcase side (P1) decreases.
3. The reaction force of spring (2) is overwhelmed by ambient
pressure (P2). Diaphragm (1) shuts the passage and tem-
porarily blocks the flow.
4. When the blowby gas accumulates in the crankcase, pres-
sure (P1) on the crankcase side increases, and it pushes
up diaphragm (1) again and blowby gas starts to flow.
10-76 114E-6 SERIES

KDPF
KDPF
Abbreviation for KOMATSU Diesel Particulate Filter
STRUCTURE OF KDPF
REMARK
General view
A: From VGT B: To AdBlue/DEF mixing connector

1: Inlet unit 8: KDPF outlet temperature sensor
2: Hanger bracket 9: Centralized connector box
3: Sensor bracket 10: KDOC outlet temperature sensor
4: Sensor bracket band 11: KDOC inlet temperature sensor
5: Outlet unit 12: KDPF differential pressure sensor port
6: KCSF unit 13: KDPF differential pressure sensor
7: KDOC unit 14: KDPF differential pressure sensor port
Structure
• KDPF consists of inlet unit (1) to introduce the exhaust gas, KDOC unit (7) to store the oxidation catalyst,
KCSF unit (6) to store the soot collecting filter equipped with catalyst, and outlet unit (5) to discharge the
exhaust gas.
• KDOC unit (7) consists of ceramic honeycomb equipped with the oxidation catalyst.
• The ceramic honeycomb is protected with a mat made of special fibers to prevent breakage of the ceramics
under the vibration condition of the engine and machine body.
114E-6 SERIES 10-77

This mat also thermally insulates the periphery of KDPF from the ceramics which becomes high tempera-
ture during operation.
• KCSF unit (6) consists of ceramic honeycomb equipped with the oxidation catalyst, similarly to KDOC unit
(7).
The inside of KCSF unit (6) consists of many cells partitioned by ceramic walls. The cells blocked on the
inlet side and those blocked on the outlet side are arranged alternately.
• KDPF is equipped with KDPF temperature sensor (assembly of KDOC inlet temperature sensor, KDOC out-
let temperature sensor, and KDPF outlet temperature sensor) and the differential pressure sensor (assem-
bly of KDPF differential pressure sensor and KDPF outlet pressure sensor).
Combination of temperatures detected by these 3 temperature sensors is used to monitor that KCSF unit
(6) and KDOC unit (7) are functioning normally, and to troubleshoot various components.
The differential pressure sensor monitors accumulation of soot in KCSF unit (6) by sensing the pressure
difference between both sides of KCSF unit (6), and uses the obtained data for troubleshooting of various
components, similarly to the temperature sensor.
FUNCTION OF KDPF
A: Flow of exhaust gas
1: KDOC (oxidation catalyst)
2: KCSF
3: Seal (ceramic made)
4: Cell
5: Ceramics honeycomb
• KDPF purifies the exhaust gas by catching large amount of
chainlike soot or PM (Particulate Matter such as soot)
which is contained in the engine exhaust gas.
• KDOC (oxidation catalyst) (1) oxidizes NO (nitrogen mon-
oxide) contained in the exhaust gas into NO 2 (nitrogen di-
oxide), and regenerates (*1) KCSF.
• KCSF (2) captures soot.
• Accumulated soot in KCSF (2) in operation range where
the temperature of exhaust gas is relatively high state is
naturally oxidized and burnt away by the effect of KDOC
(oxidation catalyst) (1). (This is called “passive regenera-
tion”)
REMARK
“Passive regeneration” cannot be performed if the light
load operation and low temperature state of the exhaust
gas continue. Accumulated soot is gradually increased.
• Engine controller always monitors 2 soot accumulation values and compares them. One is presumed soot
accumulation based on the engine operating conditions, and the other is the calculated soot accumulation
based on the signal from the differential pressure sensor which is attached to KCSF (2).
• If the amount of accumulated soot and the temperature of engine exhaust gas exceed the specified level,
engine controller performs “automatic regeneration” to burn (oxydize) the soot.
While performing automatic regeneration, the engine controller calculates the exhaust gas temperature at
KDOC inlet and exhaust gas volume, and controls the engine to raise the temperature of engine exhaust
gas. (This is called “exhaust gas temperature raise control”)
The temperature of engine exhaust gas at KDOC inlet is controlled by the fuel amount injected from the
injector, and exhaust gas volume is controlled by VGT.
The engine controller enhances the oxidation power in KDOC (1) by raising the temperature of engine ex-
haust gas automatically, and improves combustion efficiency of soot captured in KCSF (2).
10-78 114E-6 SERIES

REMARK
When regeneration function on the machine monitor is disabled, or outside air temperature is extremely
low, or continuous light load operation is carried out, relatively low exhaust temperature continues. In such
case, “automatic regeneration” is not performed and the amount of soot accumulation is increased.
• If “automatic regeneration” is not performed due to the excess amount of accumulated soot in KCSF (2),
perform “manual stationary regeneration” to burn (oxydize) the soot and reduce the amount of soot inside
KCSF (2).
REMARK
Excessive amount of the soot interferes the flow of exhaust gas to worsen fuel consumption and engine
combustion state. It may lead to other failures.
If the amount of soot increases further, “manual stationary regeneration” cannot be performed safely. This
will result in a KDPF failure and replacement is unavoidable. Make sure to follow the procedures in the Op-
eration and Maintenance Manual when performing “manual stationary regeneration”.
*1: Soot purification (oxidation) treatment
TYPES OF REGENERATION FUNCTIONS

Regeneration means to purify (oxidize) the soot accumulated on the soot collecting filter (KCSF) in KDPF or
maintain the urea SCR system normal.
Passive regeneration
When the exhaust temperature of the engine is relatively high, the oxidation power of soot in the exhaust gas
components is increased by the catalysis of KDOC to oxidize (burn) the soot accumulated in KCSF naturally.
Active regeneration (engine exhaust temperature rise control + fuel dosing)
• Automatic regeneration
• When soot is accumulated more than a certain level or the urea SCR system makes a request to main-
tain itself normal, the engine enters the exhaust temperature rise control mode (*1) and performs fuel
dosing (*2) and starts regeneration automatically.
The automatic regeneration is also performed by the direction from the engine controller at a set time
after the previous regeneration, regardless of soot accumulation in KCSF.
*1: Control to increase the engine exhaust temperature by controlling the fuel injection timing or VGT.
*2: Fuel injection performed to accelerate regeneration by increasing the exhaust temperature.
• Manual stationary regeneration
• When the exhaust temperature does not reach a certain level, depending on the operating condition of
the machine, or when the operator disables regeneration, the automatic regeneration is not performed
and accumulated soot in KCSF increases. Also, when the automatic regeneration is performed upon
receiving a request from the urea SCR system, the exhaust temperature may not reach a certain level,
depending on the operating condition of the machine. In these cases, a request for the manual station-
ary regeneration request is displayed on the machine monitor, and the operator must perform regener-
ation by the operation on the machine monitor screen.
In addition, when the engine controller is replaced or ash in KCSF is washed, a serviceman performs
regeneration by the operation on the machine monitor screen (“active regeneration for service”).
114E-6 SERIES 10-79

NOTICE
• For the procedure to start and stop the regeneration of KDPF, see the Operation and Maintenance
Manual for each machine.
• Always use ultra low-sulfur diesel fuel. If any fuel other than the specified one is used, it can cause a
failure in KDPF.
• Always use specified Komatsu genuine engine oil applicable to KDPF. If any oil other than the speci-
fied one is used, it can clog KDPF quickly, and that can increase fuel consumption and cause a fail-
ure in KDPF.
• Do not modify KDPF body and exhaust pipe. If modification is made, KDPF cannot operate normally
and may have trouble.
• Do not give strong impacts to KDPF by standing on it, dropping it, or hitting it, etc. KDPF has ceram-
ic parts in it, and they may be broken by a strong impact.
• During the “automatic regeneration” and the “manual stationary regeneration”, especially at low
temperature, white smoke may be discharged through the exhaust pipe outlet for a short time. This
phenomenon is not abnormal. Be sure to perform regeneration in a well-ventilated area, since car-
bon monoxide may be generated.
• During the “automatic regeneration” and the “manual stationary regeneration”, the temperature of
the exhaust gas discharged from the exhaust pipe may increase above 650 °C. To prevent a fire,
check that there is no combustible around the exhaust pipe. Also, check that there is no person in
the blow-out direction of the exhaust gas and confirm the safety around the machine.
REMARK
• If the mixing ratio of the bio-fuel in the diesel fuel is high, the regeneration of KDPF may become more fre-
quent.
• Even when soot is not accumulated much, the engine controller may start “automatic regeneration”. This is
automatic regeneration to maintain the function of KDPF or urea SCR system normal, and is not an abnor-
mal operation. Automatic regeneration to maintain the function of urea SCR system normal or manual sta-
tionary regeneration takes approximately 1 hour.
• During the “automatic regeneration” and the “manual stationary regeneration”, VGT operates automatically
and the engine sound changes. Also, the exhaust gas flow rate in KDPF changes, and accordingly the ex-
haust sound changes. These phenomena are not abnormal.
• During the “automatic regeneration” and the “manual stationary regeneration”, the exhaust pipe may smell
different from usual. This is not abnormal phenomenon.
• KDPF has “KDPF dry operation” function to prevent excessive accumulation of unburnt fuel in KDPF when
operation is continued at relatively low temperature for long hours.This is a function that the engine control-
ler increases the engine exhaust temperature automatically and performs dry operation of KCSF when the
set condition is satisfied. When the automatic dry operation is insufficient for the treatment, manual station-
ary regeneration may be required.
• The standard temperature of KDPF is shown below.
KDOC In (KDOC inlet KDOC Out (KDOC out- KDPF Out (KDPF outlet
temperature sensor) let temperature sensor) temperature sensor)
While regeneration is not performed
100 to 250 °C
(idling state)
While regeneration is performed (ther-
100 to 250 °C 400 to 550 °C
mal mode)
10-80 114E-6 SERIES

10 STRUCTURE AND FUNCTION LUBRICATION SYSTEM
LUBRICATION SYSTEM
LAYOUT DRAWING OF LUBRICATION SYSTEM PARTS
REMARK
1: EGR valve 3: VGT

2: Engine boost oil pump 4: Engine oil filter
114E-6 SERIES 10-81

LUBRICATION SYSTEM 10 STRUCTURE AND FUNCTION
LUBRICATION SYSTEM CIRCUIT DIAGRAM
1: Strainer 11: Engine boost oil pump

2: Engine oil pump 12: Regulator valve
3: Regulator 13: EPC valve (for VGT)
4: Bypass valve 14: VGT
5: Engine oil cooler 15: EPC valve (for EGR valve)
6: Engine oil filter 16: EGR valve
7: Engine oil filter safety valve 17: Piston cooling gallery
8: VGT lubrication 18: Piston lubrication
9: Main gallery lubrication 19: Engine oil pan
10: Lubrication of each bearing
10-82 114E-6 SERIES

ENGINE OIL PUMP

STRUCTURE OF ENGINE OIL PUMP
REMARK
1: Drive gear (number of teeth: 24) 6: Idler gear (number of teeth: 23)
2: Bushing 7: Back plate
3: Drive shaft 8: Inner rotor (drive rotor)
4: Housing 9: Outer rotor (planetary rotor)
5: Idler shaft
SPECIFICATIONS OF ENGINE OIL PUMP

Type: Trochoid pump
Speed: Engine speed x 1.75
FUNCTION OF ENGINE OIL PUMP

• The engine oil pump pressure-feeds engine oil to lubricate the inside of the engine.
• This is installed in the circuit between the engine oil pan and regulator valve and driven with the power from
the crankshaft.
114E-6 SERIES 10-83

ENGINE BOOST OIL PUMP

STRUCTURE OF ENGINE BOOST OIL PUMP
REMARK
A: Discharge opening B: Suction opening

1: Regulator valve
SPECIFICATIONS OF ENGINE BOOST OIL PUMP

Engine boost oil pump
Type: Gear pump
Speed: Engine speed x 1.0
Regulator valve
Cracking pressure: 1.43±0.1 MPa {14.6±1 kg/cm2}
FUNCTION OF ENGINE BOOST OIL PUMP

• The engine boost oil pump pressure-feeds engine oil to drive EGR valve and VGT.
• This is installed in the circuit from the main gallery to EGR valve and VGT circuit, and driven with the power
from the camshaft.
• This pump supplies hydraulic pressure to the 4 circuits of EGR valve drive, EGR valve control, VGT drive,
and VGT control.
10-84 114E-6 SERIES

ENGINE OIL FILTER

STRUCTURE OF ENGINE OIL FILTER
REMARK
1: Filter cartridge 3: Safety valve

2: Plug 4: Filter head
SPECIFICATIONS OF ENGINE OIL FILTER

Filtering area of engine oil filter : 0.44 m2 (full flow)
Cracking pressure of safety valve : 343±19 kPa {3.5±0.2 kg/cm2}
FUNCTION OF ENGINE OIL FILTER

• When the engine oil lubricate the inside of the engine, impurities such as carbon, sludge, metal powder, etc.
are mixed in it.
This filter is installed to remove those impurities.
• It is equipped with an engine oil filter safety valve which bypasses the engine oil to each part of the engine
when the filter is clogged.
• It is remote-mounted on some machine models for the ease of replacement of the filter cartridge.
114E-6 SERIES 10-85

ENGINE OIL COOLER

STRUCTURE OF ENGINE OIL COOLER
REMARK
a: Engine oil pump drive gear b: Crankshaft gear

1: Engine oil cooler core assembly 3: Safety valve
2: Engine oil pump 4: Regulator valve
SPECIFICATIONS OF ENGINE OIL COOLER

Number of elements: 15
10-86 114E-6 SERIES

SAFETY VALVE OF ENGINE OIL FILTER

STRUCTURE OF SAFETY VALVE OF ENGINE OIL FILTER
A: To engine oil cooler D: From engine oil filter

B: From engine oil pump E: From engine oil filter
C: To engine oil pan F: To main gallery
1: Plug 4: Engine oil filter
2: Spring 5: Engine oil filter safety valve
3: Plunger valve 6: Engine oil cooler
SPECIFICATIONS OF SAFETY VALVE OF ENGINE OIL FILTER

Cracking pressure: 345 kPa {3.5 kg/cm2}
114E-6 SERIES 10-87

ENGINE OIL PAN

STRUCTURE OF ENGINE OIL PAN
REMARK
1: Engine dipstick 4: Engine oil level sensor

2: Engine oil suction pipe 5: Engine oil drain valve
3: Engine oil pan
10-88 114E-6 SERIES

10 STRUCTURE AND FUNCTION FUEL SYSTEM
FUEL SYSTEM
LAYOUT DRAWING OF FUEL SYSTEM PARTS
REMARK
A: From fuel prefilter B: To fuel main filter

1: Main filter 6: Common rail
2: Injector 7: High-pressure pipe
3: Inlet connector 8: Pressure limiter valve
4: Check valve 9: Feed pump
5: Supply pump
114E-6 SERIES 10-89

FUEL SYSTEM 10 STRUCTURE AND FUNCTION
FUEL SYSTEM CIRCUIT DIAGRAM
1: Fuel main filter 8: Water separator

2: Supply pump 9: Fuel prefilter
3: Injector 10: Priming pump
4: Common rail 11: Lift pump
5: Check valve 12: ECM cooling plate
6: Pressure limiter valve 13: Check valve
7: Fuel tank 14: Feed pump
FUNCTION OF FUEL SYSTEM

• The fuel injection system is high-pressure common rail type and is controlled electronically.
The high-pressure common rail type consists of 4 main components of feed pump (low-pressure fuel pump)
(14), supply pump (high-pressure fuel pump) (2), common rail (4), and injector (3).
• The fuel system uses injector (3) driven by the solenoid.
• Engine controller (EC) controls fuel supply to each injector (3) and injection timing by driving the solenoid in
injector (3).
• The engine controller controls the injection rate and injection timing of fuel more accurately by controlling
the solenoid electronically.
10-90 114E-6 SERIES

EC: Engine controller

PS: Common rail pressure sensor
2: Supply pump
3: Injector
4: Common rail
• Supply pump (2) sends high-pressure fuel to common rail

(4). The high-pressure fuel is stored in common rail (4).
• Engine controller (EC) controls fuel supply to each injector
(3) and injection timing by driving the solenoid in injector
(3).
• The fuel flows to feed pump (14) through the fuel prefilter
equipped with the water separator.
• The fuel is discharged from feed pump (14), filtrated by
fuel main filter (1), and sent to supply pump (2).
• The fuel flowing into supply pump (2) is pressurized high
by 2 plunger pumps.
• Common rail (4) stores high-pressure fuel and works as a
fuel manifold to distribute the fuel to the supply lines for
each injector (3).
• Common rail (4) has common rail pressure sensor (PS).
Engine controller (EC) monitors the pressure supplied from
supply pump (2) to common rail (4).
• The pressure sensed by common rail pressure sensor
(PS) is used by engine controller (EC) to adjust the fuel
output pressure of supply pump (2).
• In common rail (4), pressure limiter valve (6) (common rail
pressure relief valve) is also installed.
• Pressure limiter valve (6) is a safety valve which releases the pressure in common rail (4) when it exceeds
the set value.
• The fuel released by pressure limiter (6) is returned to the fuel tank through the fuel return circuit connected
to common rail (4).
• The high-pressure fuel flows in the side of injector (3). When the solenoid is energized, the internal needle
rises and the fuel is injected.
Function of injector and inlet connector
NOTICE
Clearance in the injector nozzle is so small that entrance
of dust causes sticking of injector nozzle.
Clean all around the fuel connecting part before perform-
ing service for fuel system, and cover all the openings of
fuel connecting part.
114E-6 SERIES 10-91

1: Inlet connector
7: Common rail
11: High-pressure pipe
17: Injector
18: Retaining nut
• The high-pressure fuel is supplied by high-pressure pipe
(11) and inlet connector (1) from common rail (7) to injector
(17).
• Inlet connector (1) is pressed against the body of injector
(17) by tightening retaining nut (18) of inlet connector (1),
and high-pressure pipe (11) is connected to inlet connector
(1) by tightening the sleeve nut.
• Connection of inlet connector (1) and high-pressure pipe
(11) is very important. If retaining nut (18) is tightened in-
sufficiently, the contact faces are not sealed and the high-
pressure fuel leaks.
• If retaining nut (18) is tightened too strong, inlet connector
(1) and injector (17) are deformed, and the high-pressure
fuel also leaks.
• You cannot check it visually since this leakage occurs in-
side. As a result, a failure code may be displayed, the out-
put may decrease, and the engine may have starting trou-
ble.
• An edge filter is installed in inlet connector (1) to break
small foreign material mixed in the fuel. The edge filter
breaks particles with high pulsation pressure so that they
can pass through the fuel passage in injector (17).
• All of injectors (17) return the fuel to the common return
circuit in the cylinder head.
• Excessive fuel returns from the return circuit to the fuel
tank through the spill tube installed to the rear of the cylin-
der head.
• A check valve is installed to the rear of the cylinder head to
which the spill tube is installed.
• The cylinder head and spill tube are connected by a quick disconnect fitting or an eye joint.
10-92 114E-6 SERIES

SUPPLY PUMP
STRUCTURE OF SUPPLY PUMP
E
3
C
1
D
A
B
Z
Z
A4E12501
A: Fuel inlet (from fuel prefilter) D: Fuel outlet (to common rail)
B: Fuel outlet (to fuel main filter) E: Drain (to fuel tank)
C: Fuel outlet (from fuel main filter)
1: Feed pump 3: IMV solenoid connector
2: Supply pump
$(
114E-6 SERIES 10-93

4: lift pump

$(
5: priming pump 7: pump camshaft

6: supply pump actuator housing
FUNCTION OF SUPPLY PUMP

• The supply pump consists of the feed pump (low-pressure pump) and supply pump (high-pressure pump)
and is driven with the power from the camshaft.
• The feed pump (low-pressure pump) supplies the fuel to the fuel main filter.
• The supply pump (high-pressure pump) pressure-feeds the fuel to the common rail.
OPERATION OF SUPPLY PUMP
$(
1. The lift pump(4) functions as priming pump(5) when the engine is started.
2. The lift pump(4) operates for approximately 60 seconds after the engine is started. After the engine is start-
ed, the feed pump(1) keeps priming without assistance from the lift pump(4).
10-94 114E-6 SERIES


$(
3. The fuel discharged from the feed pump(1) is sent to the high-efficiency fuel main filter. The filtrated fuel is
returned to the supply pump actuator housing(6).
4. The supply pump(2) is driven by the camshaft of the engine. The feed pump(1) is driven by the pump cam-
shaft(7) through the internal coupling.
5. The 2 plunger pumps are driven by the pump camshaft(7) having 3 protrusions. The pump camshaft(7) is
supported on the taper roller bearing inside the cam housing module.
6. The bearing which supports the pump camshaft(7) and the pump camshaft(7) itself, as well as the tappet
and roller, are lubricated with the engine oil. Only these of the components in the pump are lubricated with
the engine oil.
7. The engine oil is supplied to the supply pump(2) through the drilled hole in the engine gear housing. It flows
from the engine gear housing to the cam housing of the supply pump(2).
8. The small O-ring in the hollow on the back of the engine gear housing is used to seal this passage.
9. The pressure from the feed pump(1) is supplied to the supply pump actuator. The supply pump actuator is
controlled by ECM to maintain proper common rail pressure.
10. The air bleeder orifice installed to the supply pump actuator housing(6) facilitates bleeding air from the fuel
supply system.
11. Since the air bleeder orifice is installed, a part of the fuel supplied from the gear pump is constantly drained.
12. The fuel to be measured after flowing through the supply pump actuator flows into the inlet drilled hole in
the supply pump(2), then flows through the check valve on the inlet side, pushes down the plunger pump,
and enters the pump chamber.
13. When the camshaft pushes up the plunger pump, the fuel reaches the common rail pressure and pushes
up the check valve on the outlet side. The fuel flows into the outlet drilled hole of the supply pump(2), then
flows to the common rail through the high-pressure fuel line.
114E-6 SERIES 10-95

FUEL PREFILTER
STRUCTURE OF FUEL PREFILTER
REMARK
A: Fuel outlet B: Fuel inlet

1: Connector 5: Hand primer (priming pump)
2: Clear bowl 6: O-ring
3: Filter cartridge 7: Drain valve
4: Water-in-fuel sensor
FUNCTION OF FUEL PREFILTER

• The fuel flows from the fuel tank through the fuel prefilter to the supply pump.
• The fuel prefilter is a fuel filter having a water separator, which separates water accumulated in the filter.
• A water-in-fuel sensor is installed to sense the quantity of the separated water.
10-96 114E-6 SERIES

FUEL MAIN FILTER

STRUCTURE OF FUEL MAIN FILTER
REMARK
1: Pressure pickup plug 3: Filter cartridge

2: Filter head
FUNCTION OF FUEL MAIN FILTER

• The fuel flows from the feed pump (low-pressure pump) to the supply pump (high-pressure pump) through
the fuel main filter.
• The fuel main filter removes impurities mixed in the fuel.
• It is remote-mounted on some machine models for ease of replacement of the cartridge.
114E-6 SERIES 10-97

COOLING SYSTEM 10 STRUCTURE AND FUNCTION
COOLING SYSTEM
LAYOUT DRAWING OF COOLING SYSTEM PARTS
REMARK
A: From radiator B: To radiator

1: EGR cooler 3: Water pump
2: VGT 4: Engine oil cooler
10-98 114E-6 SERIES

10 STRUCTURE AND FUNCTION COOLING SYSTEM
COOLING SYSTEM CIRCUIT DIAGRAM
a: Flow when thermostat is open b: Flow when thermostat is closed

1: Radiator 9: Water manifold
2: Thermostat 10: Coolant temperature sensor
3: Cylinder head 11: KCCV
4: VGT 12: AdBlue/DEF injector
5: EGR cooler 13: Distribution block
6: Cylinder block 14: Air conditioner unit (heater section)
7: Engine oil cooler 15: AdBlue/DEF tank heating valve
8: Water pump 16: AdBlue/DEF tank
114E-6 SERIES 10-99

A: Coolant inlet from radiator F: Return of coolant from cylinder head

B: Water pump intake opening G: Block upper water manifold
C: Coolant flow through lubricating oil cooler H: Thermostat bypass
D: Block lower water manifold (to cylinder) J: Return of coolant to radiator
E: Supply of coolant to cylinder head
10-100 114E-6 SERIES

DRIVE PULLEY
STRUCTURE OF DRIVE PULLEY (BULLDOZER)
REMARK
A: To radiator B: From radiator

1: V-belt 4: Water pump
2: Crankshaft pulley 5: Alternator
3: Auto-tensioner 6: Accessory pulley
REMARK
Auto-tensioner (3) automatically adjusts the tension of V-belt (1) at a constant level.
STRUCTURE OF DRIVE PULLEY(HYDRAULIC EXCAVATOR)

REMARK
114E-6 SERIES 10-101

A: To radiator B: From radiator

1: Crankshaft pulley 5: Water pump
2: Fan belt 6: Alternator
3: Alternator belt 7: Auto-tensioner for fan belt
4: Auto-tensioner for alternator belt 8: Fan pulley
REMARK
• Auto-tensioner (7) for fan belt automatically adjusts the tension of fan belt (2) at a constant level.
• Auto-tensioner (4) for alternator belt automatically adjusts the tension of alternator belt (3) at a constant lev-
el.
10-102 114E-6 SERIES

WATER PUMP
STRUCTURE OF WATER PUMP
REMARK
General view
A: Coolant inlet B: Coolant outlet (to each part of engine)

1: Impeller 4: Pulley
2: Water seal 5: Drive shaft
3: Pump body
114E-6 SERIES 10-103

THERMOSTAT
STRUCTURE OF THERMOSTAT
REMARK
1: Piston 4: Bypass spring

2: Spring 5: Bypass valve
3: Case
SPECIFICATIONS OF THERMOSTAT
Bulldozer series
Cracking temperature: 70±2 °C
Full open temperature: 83 °C
Valve lift: Min. 10 mm
Hydraulic excavator series
Cracking temperature: 81±2 °C
Full open temperature: 94 °C
Valve lift: Min. 10 mm
10-104 114E-6 SERIES

10 STRUCTURE AND FUNCTION COMPONENT PARTS OF ELECTRICAL SYSTEM
ELECTRICAL SYSTEM
COMPONENT PARTS OF ELECTRICAL SYSTEM
ALTERNATOR
STRUCTURE OF ALTERNATOR WITH BUILT-IN REGULATOR (OPEN TYPE, 90A)
REMARK
General view and circuit diagram
1: Alternator 6: Internal wiring diagram

2: Alternator pulley 6A: Initial excitation resistance
3: Terminal B 6B: Regulator
4: Terminal E 6C: Field coil
5: Terminal R
SPECIFICATIONS OF ALTERNATOR WITH BUILT-IN REGULATOR (OPEN TYPE,

90A)
Type: Open type manufactured by NIKKO DENKI (brushless)
Specifications: 24 V, 90 A
114E-6 SERIES 10-105

COMPONENT PARTS OF ELECTRICAL SYSTEM 10 STRUCTURE AND FUNCTION
Number of pulley grooves: 8

Pulley outside diameter: 80 mm
Weight: 19 kg
STRUCTURE OF ALTERNATOR WITH BUILT-IN REGULATOR (OPEN TYPE,

140A)
REMARK
1: Alternator (body) 6A: Initial excitation resistance

2: Alternator pulley 6B: Regulator
3: Terminal R 6C: Field coil
4: Terminal B 6D: Condenser
5: Terminal E 6E: stator
6: Internal wiring diagram 6F: Rectifying diode
10-106 114E-6 SERIES

SPECIFICATIONS OF ALTERNATOR WITH BUILT-IN REGULATOR (OPEN TYPE,

140A)
Type: Open type manufactured by NIKKO DENKI (brushless)
Specifications: 24 V, 140 A
Number of pulley grooves: 8
Pulley outside diameter: 85 mm
Weight: 16.5 kg
114E-6 SERIES 10-107

STARTING MOTOR
STRUCTURE OF STARTER MOTOR WITH BUILT-IN SAFETY RELAY (7.5kW)
REMARK
E: To ground R: To alternator terminal R

S: To starting switch terminal C
1: Pinion 7: External wiring diagram
2: Magnetic switch 7A: Safety relay section
3: Starting motor (body) 7B: Starting motor section
4: Terminal B 8: Connector type
5: Terminal C Type A: 2P connector (male)
6: Air vent for water-resistance test Type B: 2P drip proof connector (male)
SPECIFICATIONS OF STARTER MOTOR BUILT IN SAFETY RELAY (7.5kW)

Type: Manufactured by NIKKO DENKI, water-resistant, oil-resistant
Specifications: 24 V, 7.5 kW
Number of teeth of pinion: 12
10-108 114E-6 SERIES

Weight: 15.5 kg
Connector type: B
STRUCTURE OF STARTER MOTOR WITH BUILT-IN SAFETY RELAY (11kW)

REMARK
E: To ground R: To alternator terminal R

S: To starting switch terminal C
1: Pinion 7: Outside wiring diagram (2-pole connector type)
2: Starting motor (body) 7A: Safety relay section
3: Magnetic switch 7B: Starting motor section
4: Terminal B Type A: 2P connector (male)
5: Terminal C Type B: 2P drip proof connector (male)
6: Safety relay
SPECIFICATIONS OF STARTER MOTOR BUILT IN SAFETY RELAY (11kW)

Type: Manufactured by NIKKO DENKI, water-resistant, oil-resistant
Specifications: 24 V, 11 kW
Number of teeth of pinion: 12
114E-6 SERIES 10-109

Weight: 18 kg
Connector type: B
10-110 114E-6 SERIES

ENGINE WIRING HARNESS

STRUCTURE OF ENGINE WIRING HARNESS
REMARK
General view
No. Connector Connector label name

1 Connector box INTER-CONNECT
2 Charge (boost) pressure and temperature sensor BOOST PRESS & IMT
114E-6 SERIES 10-111

No. Connector Connector label name

3 Common rail pressure sensor FUEL RAIL PRESS
4 NE (crankshaft) speed sensor CRANK SENSOR
5 Engine controller connector J2 ECM J2
6 Engine oil pressure switch OIL PRESSURE SWITCH
7 Engine controller connector J1 ECM J1
8 Connector to machine wiring harness OEM CONNECTION
9 Tool port TOOL PORT
10 Feed pump FUEL LIFT PUMP
11 Terminator port TERMINATOR PORT
12 Bkup (camshaft) speed sensor CAM SENSOR
13 Coolant temperature sensor COOLANT TEMP.
14 Supply pump connector INLET METERING VALVE
15 Ambient pressure sensor AMB AIR PRESSURE
16 Connector to injector wiring harness #1 & #2 INJECTOR CYL 1 & 2
10-112 114E-6 SERIES

ENGINE CONTROLLER
STRUCTURE OF ENGINE CONTROLLER
General view
FUNCTION OF ENGINE CONTROLLER

• The employed engine controller is jointly developed by Komatsu and Cummins.
• The engine controller calculates the input signals from sensors installed to various portions, and outputs
them to control the engine properly.
• The engine controller commonly possesses the information of other controllers mounted on the machine
through the network (CAN) and controls the engine and machine properly.
• Since the engine controller is mounted on the engine, its field serviceability is improved.
• It is mounted through rubber vibration isolators to reduce the vibration transmitted to it.
INPUT AND OUTPUT SIGNALS OF ENGINE CONTROLLER

Delphi96Pin “J1”
Pin No. Signal name Input/Output
Ground/Shield/
1 Injector #1 (-)
Return
Ground/Shield/
2 Injector #2 (-)
Return
Ground/Shield/
3 Injector #3 (-)
Return
4 (*1) -
5 (*1) -
114E-6 SERIES 10-113


6 (*1) -
7 (*1) -
8 (*1) -
9 Sensor power supply relay Output
Ground/Shield/
10 IMV (-)
Return
11 IMV (+) Output
12 (*1) -
13 EGR valve solenoid (+) Output
14 Lift pump (+) Output
15 Lift pump (+) Output
Ground/Shield/
16 Turbocharger speed (-)
Return
17 Turbocharger speed (+) Input
18 Engine Bkup speed sensor Input
19 (*1) -
20 (*1) -
21 (*1) -
22 (*1) -
23 (*1) -
24 (*1) -
25 Injector #1 (+) Output
28 (*1) -
29 (*1) -
30 (*1) -
31 Engine NE speed sensor Input
32 Mass air flow (MAF) sensor Input
33 (*1) -
34 (*1) -
35 (*1) -
36 (*1) -
37 (*1) -
Ground/Shield/
38 Lift pump (-)
Return
Ground/Shield/
39 Lift pump (-)
Return
40 (*1) -
41 (*1) -
10-114 114E-6 SERIES


42 (*1) -
43 (*1) -
44 Ambient pressure sensor Input
45 Charge pressure sensor Input
46 (*1) -
47 (*1) -
48 (*1) -
52 Engine oil pressure switch Input
53 (*1) -
Ground/Shield/
54 GND
Return
Ground/Shield/
55 GND
Return
Ground/Shield/
56 GND
Return
Ground/Shield/
57 GND
Return
Ground/Shield/
58 GND
Return
59 (*1) -
60 (*1) -
61 Intake air temperature sensor Input
62 Charge temperature sensor Input
63 Crankcase pressure sensor Input
64 (*1) -
65 (*1) -
66 (*1) -
67 VGT position sensor Input
68 (*1) -
69 (*1) -
70 Datalink3 (+) (KOMNET/r) Communication
71 (*1) -
72 (*1) -
Ground/Shield/
73 Injector #4 (-)
Return
Ground/Shield/
74 Injector #5 (-)
Return
114E-6 SERIES 10-115


Ground/Shield/
75 Injector #6 (-)
Return
Ground/Shield/
76 EGR valve solenoid (-)
Return
77 (*1) -
78 Sensor 5 V power supply Power supply
83 Coolant temperature sensor Input
84 (*1) -
85 Engine oil pressure sensor Input
86 (*1) -
87 Common rail pressure sensor Input
88 EGR valve lift sensor Input
89 (*1) -
90 (*1) -
91 (*1) -
92 (*1) -
93 (*1) -
94 Datalink3 (-) (KOMNET/r) Communication
95 (*1) -
96 (*1) -
*1: Never connect these pins. Malfunctions or failures may occur.

Delphi96Pin “J2”
1 Power supply (+24 V, continuous) Power supply
Ground/Shield/
2 VGT solenoid (-)
Return
3 AdBlue/DEF line heater relay 1 Output
4 (*1) -
5 ACC (Key switch) Input
6 AdBlue/DEF pump temperature sensor and AdBlue/DEF pump driver Input/ Output
7 AdBlue/DEF line heater relay 2 Output
10 Throttle sensor Input
11 (*1) -
10-116 114E-6 SERIES


12 (*1) -
13 Water-in-fuel sensor Input
14 (*1) -
15 (*1) -
16 AdBlue/DEF pump pressure sensor Input
17 (*1) -
18 (*1) -
19 (*1) -
20 (*1) -
21 Datalink4 (+) (Sensor controller) Communication
22 Datalink4 (+) (KOMNET/c) Communication
23 (*1) -
24 (*1) -
29 (*1) -
30 (*1) -
31 (*1) -
Ground/Shield/
32 GND
Return
Ground/Shield/
33 GND
Return
34 (*1) -
35 (*1) -
36 (*1) -
37 (*1) -
38 AdBlue/DEF line heater 2 Input
39 AdBlue/DEF line heater 1 Input
40 (*1) -
41 KDPF differential pressure sensor Input
42 KDPF outlet pressure sensor Input
(*1): Machine equipped with fuel control dial
43 -
Idle validation switch 2: Machine with accelerator pedal
(*1): Machine equipped with fuel control dial
44 -
Idle validation switch 1: Machine with accelerator pedal
45 Datalink4 (-) (Sensor controller) Communication
46 Datalink4 (-) (KOMNET/c) Communication
114E-6 SERIES 10-117


47 (*1) -
48 System operating lamp Output
Ground/Shield/
49 Power GND
Return
Ground/Shield/
50 Power GND
Return
Ground/Shield/
51 Power GND
Return
Ground/Shield/
52 Power GND
Return
Ground/Shield/
53 AdBlue/DEF injector (-)
Return
Ground/Shield/
54 GND
Return
55 (*1) -
56 Ambient temperature sensor Input
Ground/Shield/
57 GND
Return
58 (*1) -
59 (*1) -
60 (*1) -
Ground/Shield/
61 GND
Return
Ground/Shield/
62 GND
Return
63 (*1) -
64 (*1) -
65 Engine room temperature sensor Input
66 (*1) -
67 (*1) -
68 (*1) -
69 (*1) -
70 (*1) -
71 (*1) -
72 (*1) -
Ground/Shield/
73 Power GND
Return
74 (*1) -
75 Intake air heater relay Output
76 (*1) -
77 AdBlue/DEF injector (+) Output
78 (*1) -
10-118 114E-6 SERIES


79 AdBlue/DEF pump voltage Output
80 VGT solenoid (+) Output
81 AdBlue/DEF FCV Output
82 AdBlue/DEF tank heating valve Output
83 AdBlue/DEF pump heater relay Output
84 (*1) -
85 (*1) -
86 (*1) -
87 (*1) -
88 (*1) -
89 (*1) -
90 (*1) -
91 (*1) -
92 (*1) -
93 (*1) -
94 (*1) -
95 (*1) -
96 (*1) -
*1: Never connect these pins. Malfunctions or failures may occur.
114E-6 SERIES 10-119

SENSOR 10 STRUCTURE AND FUNCTION
SENSOR
LAYOUT DRAWING OF ENGINE SENSOR
REMARK
The figure shows D65, Model 18 as an example.
General view
10-120 114E-6 SERIES

10 STRUCTURE AND FUNCTION SENSOR
1: Mass air flow and temperature sensor 6: SCR outlet temperature sensor
2: Air cleaner clogging sensor 7: KDPF outlet temperature sensor
3: SCR temperature inlet sensor 8: KDPF inlet temperature sensor
4: Ammonia sensor 9: KDPF differential pressure and outlet pressure sen-
5: SCR outlet NOX sensor sor
Detailed drawing 1
10: Crankcase pressure sensor 14: NE speed sensor engine

11: EGR valve lift sensor 15: Common rail pressure sensor
12: Charge (boost) pressure and temperature sensor 16: Bkup speed sensor
13: Engine oil pressure switch 17: Ambient pressure sensor
114E-6 SERIES 10-121

Detailed drawing 2
18: KDPF differential pressure and outlet pressure 20: VGT speed sensor
sensor 21: VGT position sensor
19: Coolant temperature sensor
10-122 114E-6 SERIES

STRUCTURE OF AMBIENT PRESSURE SENSOR

Ambient pressure sensor is attached to the air intake cover part on the top of engine.
General view
1: Connector (FRAMATOME-3P) 2: Sensor
FUNCTION OF AMBIENT PRESSURE SENSOR

It detects ambient pressure and outputs a variable voltage.
Output characteristics
114E-6 SERIES 10-123

STRUCTURE OF ENGINE OIL PRESSURE SWITCH

Engine oil pressure switch is installed to the side of the cylinder block.
Type of contact: Normally closed contact
General view
1: Connector (DT-2P) 3: O-ring

2: Sensor
FUNCTION OF ENGINE OIL PRESSURE SWITCH

This switch senses the engine oil pressure and turns “ON” when the pressure decreases below the specified
pressure.
10-124 114E-6 SERIES

STRUCTURE OF CHARGE (BOOST) PRESSURE AND TEMPERATURE SENSOR

This is installed to the intake manifold of the engine.
General view
1: Connector (SUMITOMO-4P) 3: O-ring

2: Sensor
FUNCTION OF CHARGE (BOOST) PRESSURE AND TEMPERATURE SENSOR

This detects engine air intake pressure and temperature, and outputs a variable voltage signal for pressure and
a resistance change signal for temperature.
REMARK
“Charge pressure and temperature” means the pressure and temperature of the intake air in a turbocharged en-
gine turbocharger, and it is also called “Boost pressure and temperature” or “Intake pressure and temperature”.
114E-6 SERIES 10-125

STRUCTURE OF COOLANT TEMPERATURE SENSOR

Coolant temperature sensor is attached to the cylinder block of engine.
General view
1: Connector 3: O-ring
2: Sensor
FUNCTION OF COOLANT TEMPERATURE SENSOR

It converts the temperature variation into the resistance variation and outputs the corresponding signals.
10-126 114E-6 SERIES

STRUCTURE OF NE (CRANKSHAFT) SPEED SENSOR

NE(crankshaft) speed sensor is installed to the rear side face of cylinder block.
General view
1: O-ring 3: Connector
2: Sensor
FUNCTION OF NE (CRANKSHAFT) SPEED SENSOR

It outputs pulse voltage by the rotation of the gear.
114E-6 SERIES 10-127

STRUCTURE OF Bkup (CAMSHAFT) SPEED SENSOR

General view
1: O-ring 3: Connector (FRAMATOME-3P)

2: Sensor
FUNCTION OF Bkup (CAMSHAFT) SPEED SENSOR

It outputs pulse voltage generated by rotation of the gear.
10-128 114E-6 SERIES

STRUCTURE OF COMMON RAIL PRESSURE SENSOR

This is installed to the common rail of the engine.
General view
1: Connector 2: Sensor
FUNCTION OF COMMON RAIL PRESSURE SENSOR

It detects fuel pressure and outputs a variable voltage.
114E-6 SERIES 10-129

STRUCTURE OF EGR VALVE LIFT SENSOR

This is installed to EGR valve of the engine.
General view
1: O-ring (small) 3: Sensor

2: O-ring (big) 4: Connector
FUNCTION OF EGR VALVE LIFT SENSOR

It detects EGR valve opening position and outputs a corresponding variable voltage.
The relation between stroke and output voltage is shown in the
following graph.
10-130 114E-6 SERIES

STRUCTURE OF VGT SPEED SENSOR

This is installed to VGT of the engine.
General view
1: Sensor 3: Connector
2: O-ring
FUNCTION OF VGT SPEED SENSOR

It outputs pulse voltage by the rotation of VGT turbine.
114E-6 SERIES 10-131

STRUCTURE OF VGT POSITION SENSOR

VGT position sensor is attached to VGT of engine.
General view
1: O-ring (small) 3: Sensor

2: O-ring (big) 4: Connector
FUNCTION OF VGT POSITION SENSOR

It detects the position of nozzle ring which is built in VGT and outputs a corresponding variable voltage.
The relation between stroke and output voltage is shown in fol-
lowing graph.
10-132 114E-6 SERIES

STRUCTURE OF MASS AIR FLOW AND TEMPERATURE SENSOR

“Mass air flow” is sometimes described as “MAF (Mass Air Flow)”.
Mass air flow and temperature sensor is attached to the outlet side of air cleaner.
General view
1: Connector (SUMITOMO-4P) 3: Sensor

2: O-ring
FUNCTION OF MASS AIR FLOW AND TEMPERATURE SENSOR

It converts the variations of mass air flow and temperature into the pulse voltage and the resistance variation
and outputs the corresponding signals.
114E-6 SERIES 10-133

STRUCTURE OF KDPF DIFFERENTIAL PRESSURE AND OUTLET PRESSURE

SENSOR
KDPF differential pressure and outlet pressure sensor is attached to KDPF.
General view
1: High-pressure port 3: Connector

2: Low-pressure port 4: Sensor
FUNCTION OF KDPF DIFFERENTIAL PRESSURE AND OUTLET PRESSURE

SENSOR
• It detects KDPF inlet pressure and outlet pressure and outputs a corresponding variable voltage.
• Differential pressure indicates the difference between KDPF inlet pressure detected at high-pressure port
(1) and KDPF outlet pressure detected at low-pressure port (2).
• KDPF outlet pressure detected at low-presser port (2) is outputted as an outlet pressure.
10-134 114E-6 SERIES

STRUCTURE OF CRANKCASE PRESSURE SENSOR

Crankcase pressure sensor is attached to the inlet port side of KCCV head part.
General view
1: Connector (FRAMATOME-3P) 3: O-ring

2: Sensor
FUNCTION OF CRANKCASE PRESSURE SENSOR

It detects crankcase pressure (blowby gas pressure) and outputs a corresponding variable voltage.
114E-6 SERIES 10-135

STRUCTURE OF AIR CLEANER CLOGGING SENSOR

Air cleaner clogging sensor is attached to the air cleaner outlet side.
General view
1: Adapter 3: Indicator
2: Hood 4: Connector (DT-2P)
FUNCTION OF AIR CLEANER CLOGGING SENSOR

The switch turns “ON” when the air cleaner is clogged and pressure goes below the specified pressure (nega-
tive pressure).
10-136 114E-6 SERIES

STRUCTURE OF WATER-IN-FUEL SENSOR

General view
This is installed to the clear bowl of the fuel prefilter.
1: Connector 3: Sensor
2: Tube 4: O-ring
FUNCTION OF WATER-IN-FUEL SENSOR

When this sensor detects water in the fuel, it outputs a signal.
114E-6 SERIES 10-137

20 STANDARD VALUE TABLE
114E-6 SERIES 20-1

CONTENTS 20 STANDARD VALUE TABLE
CONTENTS
STANDARD VALUE TABLE FOR ENGINE .................................................................................................... 20-9
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) ....... 20-9
STANDARD VALUE TABLE FOR ENGINE: SAA6D114E-6 (HB365LC-3)............................................. 20-13
STANDARD VALUE TABLE FOR ENGINE: SAA6D114E-6 (PC360LC-11, PC360LCI-11) .................... 20-17
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD ........................................................ 20-21
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA6D114E-6 (D65EX-18,
D65EXI-18, D65PX-18, D65PXI-18, D65WX-18) ............................................................................... 20-21
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA6D114E-6 (D65EX-18E0,
D65EXI-18E0, D65PX-18E0, D65PXI-18E0, D65WX-18E0).............................................................. 20-23
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA6D114E-6 (HB365LC-3)... 20-25
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA6D114E-6 (PC360LC-11,
PC360LCI-11).................................................................................................................................... 20-26
20-2 114E-6 SERIES

20 STANDARD VALUE TABLE ABBREVIATION LIST
ABBREVIATION LIST
the meaning.
Abbrevia-
tion
component/system)
AISS Engine
System speed.
AJSS
Automatic Retarder
the downhill.
ASR
faces.
BCV
used.
Regulator
used independently.
Closed-center Load
Sensing System
114E-6 SERIES 20-3

ABBREVIATION LIST 20 STANDARD VALUE TABLE

Abbrevia-
tion
component/system)
jector.
EGR Engine
emission of NOx.
tional Control
Structure
Forward-Neutral-Re-
verse
Communication
Plus)
Communication
Plus)
HSS
20-4 114E-6 SERIES


Abbrevia-
tion
component/system)
and communication.
Unit
trol motions.
IMA)
KCCV Engine
filters.

KCSF Engine
KDOC Engine
fler.
late Filter
assembled.
LIN
LVDS
MAF sensor.
114E-6 SERIES 20-5


Abbrevia-
tion
component/system)
Service
system
system
Open-center Load
Sensing System
load.
PCCS
pedals, and dials.
Hydraulic system
(D, PC, etc)
ROPS Cab and canopy
ISO 12117-2.
SCR Urea SCR system
devices.
20-6 114E-6 SERIES


Abbrevia-
tion
component/system)
Structure
tion of flow.
VGT Engine
VHPC Engine control
achieved.

D: Bulldozer
HD: Dump truck
WA: Wheel loader
A/C Air Conditioner
A/M Air Mix Damper
ACC Accessory
ADD Additional
AUX Auxiliary
BR Battery Relay
CW Clockwise
ENG Engine
F.G. Frame Ground
GND Ground
NC No Connection
114E-6 SERIES 20-7


S/T
Steering
STRG
SIG Signal
SOL Solenoid
STD Standard
OPT
Option
OP
PRESS Pressure
SPEC Specification
SW Switch
TEMP Temperature
T/M Transmission
20-8 114E-6 SERIES

STANDARD VALUE TABLE FOR ENGINE: SAA6D114E-6 (D65EX-18,
D65EX-18E0, D65EXI-18, D65EXI-18E0, D65PX-18, D65PX-18E0,
20 STANDARD VALUE TABLE D65PXI-18, D65PXI-18E0, D65WX-18, D65WX-18E0)
STANDARD VALUE TABLE FOR ENGINE

D65EX-18E0, D65EXI-18, D65EXI-18E0, D65PX-18, D65PX-18E0, D65PXI-18,
D65PXI-18E0, D65WX-18, D65WX-18E0)
Performance
Engine SAA6D114E-6
Standard value
Item Measurement condition Unit Repair limit
for new machine
At Max. speed
with no load 2100±50 2100±50
Engine coolant temperature: 60 (High idle)
Engine speed rpm
to 100 °C At Min. speed
with no load 825±25 825±25
(Low idle)
Air intake and exhaust system

Engine SAA6D114E-6
Standard value
for new machine
Air intake re- kPa Max. 3.73 7.47

Whole speed range
sistance { mmH2O} {Max. 380} {762}
Boost pres- kPa 120 to 160 93

At rated horsepower (gauge pressure)
sure { mmHg} {900 to 1200} {700}
Exhaust tem-
Whole speed range (20 °C) °C Max. 650 Max. 700
perature
Engine outlet
• Engine coolant tempera- (between VGT
ture: 60 to 100 °C Max. 1.5 Max. 2.0
and KDPF in-
Exhaust gas let) Bosch in-
• At rated horsepower
color dex
• After kept for 5 seconds at SCP outlet (ex-
normal condition haust pipe out- - Max. 0.5
let)
Valve clear- Intake valve 0.22 to 0.38 0.22 to 0.38

mm
ance Exhaust valve 0.48 to 0.64 0.48 to 0.64
EGR valve, At Min. speed MPa Min. 1.2 Min. 1.2
VGT driving oil with no load
pressure (Low idle) { kg/cm2} {Min. 12} {Min. 12}
• Engine coolant tempera-
ture: 75 to 85 °C Whole speed
• Hydraulic oil temperature: range
VGT control oil MPa 0.3 to 1.0 0.3 to 1.0
45 to 55 °C Oil pressure
pressure { kg/cm2} {3 to 10} {3 to 10}
fluctuation
range
114E-6 SERIES 20-9

D65PXI-18, D65PXI-18E0, D65WX-18, D65WX-18E0) 20 STANDARD VALUE TABLE
Main body
Engine SAA6D114E-6
Standard value
for new machine
Compression • Engine oil temperature: 40 to 60 °C MPa Min. 2.6 2.1

pressure • Engine speed: 250 to 280 rpm { kg/cm2} {Min. 26.5} {21.4}
Blowby pres- • At rated horsepower kPa Max. 1.96 2.94

sure • Disconnection of KCCV { mmH2O} {Max. 200} {300}
Fuel system
Engine SAA6D114E-6
Standard value for
new machine
At Max. speed Min. 480 Min. 480
Fuel pressure with no load
(High idle) kPa {Min. 4.9} {Min. 4.9}
(Low-pressure
Cranking {kg/cm2} Min. 105 Min. 105
circuit)
(Min. 150 rpm) {Min. 1.07} {Min. 1.07}
Fuel pressure
At Max. speed kPa Max. 80 Max. 80
(Low-pressure with no load
circuit (pressure (High idle) {kg/cm2} {Max. 0.82} {Max. 0.82}
difference))
• Engine coolant tem-
perature: 75 to 85 °C At Max. speed
• Hydraulic oil temper- with no load kPa
Fuel pressure (High idle) Max. 18.6 Max. 18.6
ature: 45 to 55 °C
(Return circuit)
Cranking {kg/cm2} {Max. 0.19} {Max. 0.19}
• Operating Mode: P
(Power mode) (Min. 150 rpm)
Fuel pressure • Joystick (steering,
directional, and gear
(Negative pres- kPa -27.1 to 0 -27.1 to 0
shift lever) (PCCS
sure circuit (fuel
lever): NEUTRAL {mmHg} {-203 to 0} {-203 to 0}
supply connec-
tor))
Fuel pressure At Max. speed
with no load kPa -33.9 to 0 -33.9 to 0
(Negative pres- (High idle)
sure circuit (sup- {mmHg} {-254 to 0} {-254 to 0}
ply pump))
Fuel pressure
kPa Min. 34 Min. 34
(Fuel feed pump
{mmHg} {Min. 255} {Min. 255}
outlet pressure)
20-10 114E-6 SERIES

20 STANDARD VALUE TABLE D65PXI-18, D65PXI-18E0, D65WX-18, D65WX-18E0)
Engine SAA6D114E-6
Standard value for
new machine
Supply pump
discharged vol-
ume Cranking
mℓ Min. 75 Min. 75
(Discharged vol- (Min. 150 rpm)
ume for 30 sec-
onds)
At Min. speed
Return rate from with no load Max. 350 Max. 350
supply pump (Low idle)
mℓ
(Return rate for
Cranking
30 seconds) Max. 320 Max. 320
• Engine coolant tem- (Min. 150 rpm)
Return rate from perature: 75 to 85 °C
injector • Hydraulic oil temper- At Min. speed
with no load mℓ Max. 300 Max. 300
(Return rate for ature: 45 to 55 °C
(Low idle)
45 seconds)
Return rate from
injector Cranking
mℓ Max. 100 Max. 100
(Return rate for (Min. 150 rpm)
30 seconds)
Leakage from
pressure limiter At Min. speed
valve with no load mℓ Less than 30 drops Less than 30 drops
(Leakage for 30 (Low idle)
seconds)
Lubrication system
Engine SAA6D114E-6
Standard value
for new machine
• Engine oil temperature: At rated horse- 0.34 to 0.59 0.21
Min. 80 °C power {3.5 to 6.0} {2.1}
Engine Oil • Engine oil (*1) MPa
Pressure EO10W30-LA At Min. speed { kg/cm2} Min. 0.15 Min. 0.08
EO15W40-LA with no load
EOS5W30-LA (Low idle) {Min. 1.5} {Min. 0.8}
EOS5W40-LA
Engine oil tem-
Whole speed range (oil pan) °C 80 to 110 Max. 120
perature
Oil consump-
tion
At continuous rated horsepower % Max. 0.15 Max. 0.3
(Ratio to fuel
consumption)
*1: KES diesel engine oil
114E-6 SERIES 20-11

D65PXI-18, D65PXI-18E0, D65WX-18, D65WX-18E0) 20 STANDARD VALUE TABLE
Electrical system
Engine SAA6D114E-6
Standard value
for new machine
Automatic adjust- Automatic adjust-
Tension of al- Deflection when pressed with finger at 98 N ment ment
mm
ternator belt {10 kg}
(Auto-tensioner) (Auto-tensioner)
20-12 114E-6 SERIES

20 STANDARD VALUE TABLE STANDARD VALUE TABLE FOR ENGINE: SAA6D114E-6 (HB365LC-3)
STANDARD VALUE TABLE FOR ENGINE: SAA6D114E-6 (HB365LC-3)

Performance
Engine SAA6D114E-6
Standard value
for new machine
At Max. speed
with no load rpm 2050±30 2050±30
Engine speed
(Low idle)

Engine SAA6D114E-6
Standard value
for new machine

Whole speed range
kPa 147 120
Boost pressure At rated horsepower (gauge pressure)
{ mmHg} {1100} {900}
• Engine coolant tempera- Engine outlet

ture: 60 to 100 °C (between tur- Bosch in-
Max. 2.0 Max. 2.5
bocharger and dex
Exhaust gas • Arm IN relief KDPF inlet)
color • Swing lock switch: ON
KDPF outlet
• After kept for 5 seconds at (exhaust pipe Bosch in-
Max. 0.5 Max. 0.5
normal condition dex
outlet)
Valve clear- Intake valve mm 0.22 to 0.38 0.22 to 0.38

ance Exhaust valve mm 0.48 to 0.64 0.48 to 0.64
EGR valve, At Min. speed MPa Min. 1.2 Min. 1.2
pressure (Low idle) { kg/cm2} {Min. 12.2} {Min. 12.2}
VGT control oil MPa Min. 1.2 Min. 1.2
pressure {kg/cm2} {Min. 12.2} {Min. 12.2}
fluctuation
range
Main body
Engine SAA6D114E-6
Standard value
for new machine

Blowby pres- • At rated horsepower kPa Max. 1.96 Max. 2.94

sure • Disconnection of KCCV { mmH2O} {Max. 200} {Max. 300}
114E-6 SERIES 20-13

STANDARD VALUE TABLE FOR ENGINE: SAA6D114E-6 (HB365LC-3) 20 STANDARD VALUE TABLE
Fuel system
Engine SAA6D114E-6
Standard value
for new machine
(Fuel main fil-
ter inlet pres- { kg/cm2}
Cranking Min. 105 Min. 105
sure)
(Min. 150 rpm) {Min. 1.07} {Min. 1.07}
Fuel pressure
(Low-pressure At Max. speed kPa Min. 80 Min. 80
circuit (pres- with no load
(High idle) { kg/cm2} {Min. 0.82} {Min. 0.82}
sure differ-
ence))
At Max. speed
with no load
Fuel pressure (High idle) kPa Max. 18.6 Max. 18.6
(Return circuit) • Engine coolant tempera- { kg/cm2} {Max. 0.19} {Max. 0.19}
ture: 60 to 100 °C Cranking
(Min. 150 rpm)
• Hydraulic oil temperature:
Fuel pressure 45 to 55 °C
(Negative kPa -27.1 to 0 -27.1 to 0
pressure cir-
{ mmHg} {-203 to 0} {-203 to 0}
cuit (fuel sup-
ply connector))
Fuel pressure
At Max. speed
(Negative with no load kPa -33.9 to 0 -33.9 to 0
pressure cir- (High idle) { mmHg} {-254 to 0} {-254 to 0}
cuit (supply
pump))
Fuel pressure
(Fuel feed kPa Min. 34 Min. 34
pump outlet { mmHg} {Min. 255} {Min. 255}
pressure)
20-14 114E-6 SERIES

20 STANDARD VALUE TABLE STANDARD VALUE TABLE FOR ENGINE: SAA6D114E-6 (HB365LC-3)
Engine SAA6D114E-6
Standard value
for new machine
Supply pump
discharged
volume Cranking
(Discharged (Min. 150 rpm)
volume for 30
seconds)
Return rate At Min. speed
from supply with no load Max. 350 Max. 350
pump (Low idle)
mℓ
(Return rate
Cranking
for 30 sec- Max. 320 Max. 320
onds) (Min. 150 rpm)
Return rate
ture: 60 to 100 °C
from injector At Min. speed
• Hydraulic oil temperature: with no load mℓ Max. 300 Max. 300
(Return rate
for 45 sec- 45 to 55 °C (Low idle)
onds)
Return rate
from injector
Cranking
(Return rate mℓ Max. 100 Max. 100
(Min. 150 rpm)
for 30 sec-
onds)
Leakage from
pressure limit- At Min. speed
er valve Less than 30 Less than 30
with no load mℓ
drops drops
(Leakage for (Low idle)
30 seconds)
Lubrication system
Engine SAA6D114E-6
Standard value
for new machine
• Engine coolant tempera- At rated horse- 0.34 to 0.59 0.21
ture: 60 to 100 °C power {3.5 to 6.0} {2.1}
• Working mode: P (Power
Mode)
• Neutral position of each
Engine Oil control lever and control MPa
Pressure pedal At Min. speed { kg/cm2} Min. 0.15 Min. 0.08
with no load
• Engine oil (*1) (Low idle) {Min. 1.5} {Min. 0.8}
EO10W30-LA
EO15W40-LA
EOS5W30-LA
EOS5W40-LA
Engine oil tem-
perature
114E-6 SERIES 20-15

STANDARD VALUE TABLE FOR ENGINE: SAA6D114E-6 (HB365LC-3) 20 STANDARD VALUE TABLE
Engine SAA6D114E-6
Standard value
for new machine
Oil consump-
tion
(Ratio to fuel
consumption)
Cooling system
Engine SAA6D114E-6
Standard value
for new machine
Tension of fan Deflection when pressed with finger at 98 N ment ment
mm
belt {10 kg}
Electrical system
Engine SAA6D114E-6
Standard value
for new machine
mm
20-16 114E-6 SERIES

STANDARD VALUE TABLE FOR ENGINE: SAA6D114E-6
20 STANDARD VALUE TABLE (PC360LC-11, PC360LCI-11)
STANDARD VALUE TABLE FOR ENGINE: SAA6D114E-6 (PC360LC-11,

PC360LCI-11)
Performance
Engine SAA6D114E-6
Standard value
for new machine
At Max. speed
with no load rpm 2050 ± 50 2050 ± 50
Engine speed
(Low idle)

Engine SAA6D114E-6
Standard value
for new machine

Whole speed range
kPa 167 to 207 133
Boost pressure At rated horsepower (gauge pressure)
{ mmHg} {1250 to 1550} {1000}
• Engine coolant tempera- Engine outlet

ture: 60 to 100 °C (between tur- Bosch in-
Max. 2.0 Max. 2.5
bocharger and dex
Exhaust gas • Arm IN relief KDPF inlet)
color • Swing lock switch: ON
KDPF outlet
• After kept for 5 seconds at (exhaust pipe Bosch in-
Max. 0.5 Max. 0.5
normal condition dex
outlet)
Valve clear- Intake valve mm 0.22 to 0.38 0.22 to 0.38

ance Exhaust valve mm 0.48 to 0.64 0.48 to 0.64
EGR valve, At Min. speed MPa 1.2 1.2
pressure (Low idle) { kg/cm2} {Min. 12.2} {Min. 12.2}
VGT control oil MPa 1.2 1.2
pressure {kg/cm2} {Min. 12.2} {Min. 12.2}
fluctuation
range
Main body
Engine SAA6D114E-6
Standard value
for new machine

Blowby pres- • At rated horsepower kPa Max. 1.96 2.94

sure • Disconnection of KCCV { mmH2O} {Max. 200} {Max. 300}
114E-6 SERIES 20-17

(PC360LC-11, PC360LCI-11) 20 STANDARD VALUE TABLE
Fuel system
Engine SAA6D114E-6
Standard value
for new machine
(Fuel main fil-
ter inlet pres- { kg/cm2}
Cranking Min. 105 Min. 105
sure)
(Min. 150 rpm) {Min. 1.07} {Min. 1.07}
Fuel pressure
(Low-pressure At Max. speed kPa Min. 80 Min. 80
circuit (pres- with no load
(High idle) { kg/cm2} {Min. 0.82} {Min. 0.82}
sure differ-
ence))
At Max. speed
with no load
Fuel pressure (High idle) kPa Max. 18.6 Max. 18.6
(Return circuit) • Engine coolant tempera- { kg/cm2} {Max. 0.19} {Max. 0.19}
ture: 60 to 100 °C Cranking
(Min. 150 rpm)
• Hydraulic oil temperature:
Fuel pressure 45 to 55 °C
(Negative kPa -27.1 to 0 -27.1 to 0
pressure cir-
{ mmHg} {-203 to 0} {-203 to 0}
cuit (fuel sup-
ply connector))
Fuel pressure
At Max. speed
(Negative with no load kPa -33.9 to 0 -33.9 to 0
pressure cir- (High idle) { mmHg} {-254 to 0} {-254 to 0}
cuit (supply
pump))
Fuel pressure
(Fuel feed kPa Min. 34 Min. 34
pump outlet { mmHg} {Min. 255} {Min. 255}
pressure)
20-18 114E-6 SERIES

20 STANDARD VALUE TABLE (PC360LC-11, PC360LCI-11)
Engine SAA6D114E-6
Standard value
for new machine
Supply pump
discharged
volume Cranking
(Discharged (Min. 150 rpm)
volume for 30
seconds)
Return rate At Min. speed
from supply with no load Max. 350 Max. 350
pump (Low idle)
mℓ
(Return rate
Cranking
for 30 sec- Max. 320 Max. 320
onds) (Min. 150 rpm)
Return rate
ture: 60 to 100 °C
from injector At Min. speed
• Hydraulic oil temperature: with no load mℓ Max. 300 Max. 300
(Return rate
for 45 sec- 45 to 55 °C (Low idle)
onds)
Return rate
from injector
Cranking
(Return rate mℓ Max. 100 Max. 100
(Min. 150 rpm)
for 30 sec-
onds)
Leakage from
pressure limit- At Min. speed
er valve Less than 30 Less than 30
with no load mℓ
drops drops
(Leakage for (Low idle)
30 seconds)
Lubrication system
Engine SAA6D114E-6
Standard value
for new machine
• Engine coolant tempera- At rated horse- 0.34 to 0.59 0.21
ture: 60 to 100 °C power {3.5 to 6.0} {2.1}
• Working mode: P (Power
Mode)
• Neutral position of each
Engine Oil control lever and control MPa
Pressure pedal At Min. speed { kg/cm2} Min. 0.15 Min. 0.08
with no load
• Engine oil (*1) (Low idle) {Min. 1.5} {Min. 0.8}
EO10W30-LA
EO15W40-LA
EOS5W30-LA
EOS5W40-LA
Engine oil tem-
perature
114E-6 SERIES 20-19

(PC360LC-11, PC360LCI-11) 20 STANDARD VALUE TABLE
Engine SAA6D114E-6
Standard value
for new machine
Oil consump-
tion
(Ratio to fuel
consumption)
Cooling system
Engine SAA6D114E-6
Standard value
for new machine
Tension of fan Deflection when pressed with finger at 98 N ment ment
mm
belt {10 kg}
Electrical system
Engine SAA6D114E-6
Standard value
for new machine
mm
20-20 114E-6 SERIES

RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD:
SAA6D114E-6 (D65EX-18, D65EXI-18, D65PX-18, D65PXI-18,
20 STANDARD VALUE TABLE D65WX-18)
RUNNING-IN STANDARD AND PERFORMANCE TEST

STANDARD
SAA6D114E-6 (D65EX-18, D65EXI-18, D65PX-18, D65PXI-18, D65WX-18)
Running-in standard
Engine SAA6D114E-6
Procedure
Item
1 2 3 4 5
Running time min 2 4 9 12 3
Engine speed rpm 825 1365 1560 1755 1950
Dynamometer load N { kg} 0 {0} 548 {56} 716 {73} 906 {92} 1118 {114}
Output kW{HP} 0 {0} 80 {107} 105 {141} 133 {178} 163.7 {219}
REMARK
• This table shows the values when the fan is not installed.
• The loads for the dynamometer in this table shows the value when the dynamometer arm is 716 mm long.
Performance test standard

Engine SAA6D114E-6
Max. speed with Min. speed with no
Test item Rated horsepower Max. torque
no load load
1050 Nm/
163.7 kW/
Specification value 1450 rpm
- 1950 rpm 2100 rpm 825 rpm
(Gross value) {107.1 kgm/
{219 HP/1950 rpm}
1450 rpm}
Engine speed rpm 1950 1450 2100 825
Dynamometer load N { kg} 1118 {114} 1472 {150} - -
Output (Gross value) kW{HP} 163.7 {219} - - -
Nm{ kgm 1050
Torque (Gross value) - - -
} {107.1}
sec/300
Fuel consumption - - - -
cc
Coolant temperature °C 69 to 81 69 to 81 69 to 81 69 to 81
Lubricating oil tem-
°C 80 to 110 80 to 110 80 to 110 80 to 110
perature
Lubricating oil pres- kPa 340 to 590

- - Min. 15 {Min. 1.5}
sure { kg/cm2} {3.5 to 6.0}
Exhaust temperature °C Max. 600 Max. 650 - -
114E-6 SERIES 20-21

SAA6D114E-6 (D65EX-18, D65EXI-18, D65PX-18, D65PXI-18,
D65WX-18) 20 STANDARD VALUE TABLE
REMARK
• This table shows the standard values obtained by using the JIS correction coefficients.
• Output and torque in this table shows the values when the fan is not installed, and these values differ from
specification values.
• This table shows the standard values when the air cleaner is installed, the KDPF, and the SCR are not in-
stalled and no load is applied to the alternator.
• Use ultra low-sulfur diesel fuel.
• Use EO15W40-LA as running-in lubricating oil.
20-22 114E-6 SERIES

SAA6D114E-6 (D65EX-18E0, D65EXI-18E0, D65PX-18E0,
20 STANDARD VALUE TABLE D65PXI-18E0, D65WX-18E0)

SAA6D114E-6 (D65EX-18E0, D65EXI-18E0, D65PX-18E0, D65PXI-18E0,
D65WX-18E0)
Running-in standard
Engine SAA6D114E-6
Procedure
Item
1 2 3 4 5
Running time min 2 4 9 12 3
Engine speed rpm 825 1365 1560 1755 1950
Dynamometer load N { kg} 0 {0} 548 {56} 716 {73} 906 {92} 1118 {114}
Output kW{HP} 0 {0} 80 {107} 105 {141} 133 {178} 163.7 {219}
REMARK

Engine SAA6D114E-6
no load load
1050 Nm/
163.7 kW/
Specification value 1450 rpm
- 1950 rpm 2100 rpm 825 rpm
(Gross value) {107.1 kgm/
{219 HP/1950 rpm}
1450 rpm}
Engine speed rpm 1950 1450 2100 825
Output (Gross value) kW{HP} 163.7 {219} - - -
Nm{ kgm 1050
} {107.1}
sec/300
cc
Coolant temperature °C 69 to 81 69 to 81 69 to 81 69 to 81
°C 80 to 110 80 to 110 80 to 110 80 to 110
perature
Lubricating oil pres- kPa 340 to 590

- - Min. 15 {Min. 1.5}
sure { kg/cm2} {3.5 to 6.0}
114E-6 SERIES 20-23

SAA6D114E-6 (D65EX-18E0, D65EXI-18E0, D65PX-18E0,
D65PXI-18E0, D65WX-18E0) 20 STANDARD VALUE TABLE
REMARK
20-24 114E-6 SERIES

20 STANDARD VALUE TABLE SAA6D114E-6 (HB365LC-3)

SAA6D114E-6 (HB365LC-3)
Running-in standard
Engine SAA6D114E-6
Procedure
Item
1 2 3 4 5
Running time min 1.5 4.5 9 12 3
Engine speed rpm 700 1230 1540 1775 1950
Dynamometer load N { kg} 0 {0} 34.6 {35} 692 {71} 1038 {106} 1384 {141}
Output kW{HP} 0 {0} 51 {68} 101 {136} 152 {203} 202 {271}
REMARK

Engine SAA6D114E-6
no load load
1171 Nm/1450 rpm
Specification value 202 kW/1950 rpm
- {119 kgm/ 2050 rpm 700 rpm
(Gross value) {271 HP/1950 rpm}
1450 rpm}
Engine speed rpm 1950 1450 - -
Output (Gross value) kW{HP} 202 {271} - - -
Nm{ kgm 1171
} {119}
sec/300
cc
Coolant temperature °C 83 to 95 83 to 95 - -
°C 80 to 110 80 to 110 - -
perature
Lubricating oil pres- MPa 0.34 to 0.59 Min. 0.15

- -
sure { kg/cm2} {3.5 to 6.0} {Min. 1.5}
REMARK
114E-6 SERIES 20-25

SAA6D114E-6 (PC360LC-11, PC360LCI-11) 20 STANDARD VALUE TABLE

SAA6D114E-6 (PC360LC-11, PC360LCI-11)
Running-in standard
Engine SAA6D114E-6
Procedure
Item
1 2 3 4 5
Running time min 1.5 4.5 9 12 3
Engine speed rpm 1000 1230 1540 1775 1950
Dynamometer load N { kg} 0 {0} 34.6 {35} 692 {71} 1038 {106} 1384 {141}
Output kW{HP} 0 {0} 51 {68} 101 {136} 152 {203} 202 {271}
REMARK

Engine SAA6D114E-6
no load load
1171 Nm/1450 rpm
Specification value 202 kW/1950 rpm
- {119 kgm/ 2050 rpm 1000 rpm
(Gross value) {271 HP/1950 rpm}
1450 rpm}
Engine speed rpm 1950 1450 - -
Output (Gross value) kW{HP} 202 {271} - - -
Nm{ kgm 1171
} {119}
sec/300
cc
Coolant temperature °C 83 to 95 83 to 95 - -
°C 80 to 110 80 to 110 - -
perature
Lubricating oil pres- MPa 0.34 to 0.59 Min. 0.15

- -
sure { kg/cm2} {3.5 to 6.0} {Min. 1.5}
REMARK
20-26 114E-6 SERIES

50 DISASSEMBLY AND ASSEMBLY
114E-6 SERIES 50-1

50 DISASSEMBLY AND ASSEM-
CONTENTS BLY
CONTENTS
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY ................................................................. 50-9
HOW TO READ THIS MANUAL.............................................................................................................. 50-9
COATING MATERIALS LIST..................................................................................................................50-11
SPECIAL TOOLS LIST ......................................................................................................................... 50-15
SKETCHES OF SPECIAL TOOLS........................................................................................................ 50-17
ENGINE SYSTEM ....................................................................................................................................... 50-18
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY.................................................................... 50-18
METHOD FOR DISASEMBLING ENGINE GENERALLY ............................................................... 50-19
METHOD FOR ASEMBLING ENGINE GENERALLY..................................................................... 50-50
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY ........................................................................50-102
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY ............................................................50-102
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY ...........................................................50-104
REMOVE AND INSTALL ENGINE FRONT OIL SEAL .........................................................................50-108
METHOD FOR REMOVING ENGINE FRONT OIL SEAL .............................................................50-108
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL ............................................................50-109
REMOVE AND INSTALL ENGINE REAR OIL SEAL............................................................................50-112
METHOD FOR REMOVING ENGINE REAR OIL SEAL................................................................50-112
METHOD FOR INSTALLING ENGINE REAR OIL SEAL...............................................................50-113
50-2 114E-6 SERIES

BLY ABBREVIATION LIST
ABBREVIATION LIST
the meaning.
Abbrevia-
tion
component/system)
AISS Engine
System speed.
AJSS
Automatic Retarder
the downhill.
ASR
faces.
BCV
used.
Regulator
used independently.
Closed-center Load
Sensing System
114E-6 SERIES 50-3

ABBREVIATION LIST BLY

Abbrevia-
tion
component/system)
jector.
EGR Engine
emission of NOx.
tional Control
Structure
Forward-Neutral-Re-
verse
Communication
Plus)
Communication
Plus)
HSS
50-4 114E-6 SERIES


Abbrevia-
tion
component/system)
and communication.
Unit
trol motions.
IMA)
KCCV Engine
filters.

KCSF Engine
KDOC Engine
fler.
late Filter
assembled.
LIN
LVDS
MAF sensor.
114E-6 SERIES 50-5


Abbrevia-
tion
component/system)
Service
system
system
Open-center Load
Sensing System
load.
PCCS
pedals, and dials.
Hydraulic system
(D, PC, etc)
ROPS Cab and canopy
ISO 12117-2.
SCR Urea SCR system
devices.
50-6 114E-6 SERIES


Abbrevia-
tion
component/system)
Structure
tion of flow.
VGT Engine
VHPC Engine control
achieved.

D: Bulldozer
HD: Dump truck
WA: Wheel loader
A/C Air Conditioner
A/M Air Mix Damper
ACC Accessory
ADD Additional
AUX Auxiliary
BR Battery Relay
CW Clockwise
ENG Engine
F.G. Frame Ground
GND Ground
NC No Connection
114E-6 SERIES 50-7


S/T
Steering
STRG
SIG Signal
SOL Solenoid
STD Standard
OPT
Option
OP
PRESS Pressure
SPEC Specification
SW Switch
TEMP Temperature
T/M Transmission
50-8 114E-6 SERIES

BLY HOW TO READ THIS MANUAL
RELATED INFORMATION ON DISASSEMBLY AND AS-

SEMBLY
HOW TO READ THIS MANUAL
This section describes the special tools, work procedures, and safety precautions necessary for removal, instal-
lation, 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.
Reading the special tools list
• The special tools required for removal and installation work are described in the list as symbols such as
A1, ..., X1. Part number, part name, necessity, and quantity are described.
• Details of the special tools are on “SPECIAL TOOLS LIST”. Details of sketches are on “SKETCHES OF
SPECIAL TOOLS”. Special tools required for a specified work is also described in each work procedures.
• The symbols used in the table of special tools indicate the following meanings.
■: Not substitutable, and work cannot be performed without the tool.
●: Very useful tools to use which can be substituted with commercially available tools.
Reading the work procedures
All the necessary information for the work procedure, the precautions and prior knowledge relating to the work
procedures is described step by step.
Reading the symbols
Important safety and quality portions are marked with the following symbols so that shop manual is used effec-
tively.
Symbol Item Remark
This signal indicates an extremely hazardous situation which will result in
Danger
Warning
Caution
injury or property damage around the machine if it is not avoided.
This signal indicates the weight of parts and components, and items which
Weight requires great attention to a selection of wires and working posture for
slinging work.
This signal indicates the tightening torque for portions which requires spe-
Tightening torque
cial care in assembling work.
This signal indicates a place to be coated with adhesive, grease, etc. in
Coat
assembling work.
This signal indicates a place to supply oil, coolant, etc. and the quantity.
Oil and coolant
(*1)
Draining This signal indicates a place to drain oil, coolant, etc. and the quantity.
*1:For places to supply oil, coolant, etc. and their quantities, see SPECIFICATIONS “TABLE OF FUEL, COOL-
ANT, AND LUBRICANTS”.
Reading the signal word
Signal word for notice and remark describes the following.
Symbol Item Remark
If the precaution of this signal word is not observed, the machine damage
NOTICE NOTICE
or shortening of service life may occur.
114E-6 SERIES 50-9

HOW TO READ THIS MANUAL BLY
Symbol Item Remark

REMARK Remarks This signal word contains useful information to know.
Reading the unit

International System of Units (SI) is used in this manual. For reference, units that have been used in the past
are given in { }.
50-10 114E-6 SERIES

BLY COATING MATERIALS LIST
COATING MATERIALS LIST

Coating materials which are not listed below, use the equivalent of products shown in this manual.
Adhesive
Komatsu code Part No. Capacity Container Main features and applications
• Use to prevent rubber gaskets, rubber
LT-1A 790-129-9030 150 g Tube
cushions, and cork plugs from falling off.
• Use for plastic (except polyethylene, pol-
20 g Polyethy- ypropylene, tetrafluoroethylene and vinyl
LT-1B 790-129-9050 (contained lene con- chloride), rubber, metal, and non-metal
2 pieces) tainer parts which require immediate and
strong adhesion.
• Features: Resistance to heat and chemi-
Polyethy- cals
LT-2 790-129-9180 50 g lene con-
tainer • Use to keep bolts and plugs from com-
ing loose and as sealant.
790-129-9060 Adhesive
Set of adhe- 1 kg • Use to bond and seal metal, glass and
LT-3 Pail
sive and hard- Hardener plastics.
ener 500 g
Polyethy-
LT-4 790-129-9040 250 g lene con- • Use to seal plugs for blank holes.
tainer
Holts • Heat-resistant seal used to repair en-
790-129-9120 75 g Tube
MH705 gines
• Instantaneous adhesive
Polyethy-
• Curing time: From 5 sec. to 3 min.
LT-1D 790-129-9140 50 g lene con-
tainer • Use to bond mainly metals, rubbers,
plastics, and woods.
• Instantaneous adhesive
Aron Alpha Polyethy- • Quick-curing type (max. strength is ob-

790-129-9130 2 g lene contained after 30 minutes)
201 tainer • Use to bond rubbers, plastics, and met-
als.
• General-purpose instantaneous adhe-
sive with excellent resistance to heat
Loctite
428-99-80070 20 cc Tube and impact
499
• Use for the bushing mounting faces of
axle supports.
Polyethy- • Features: Resistance to heat and chemi-

Loctite
79A-129-9110 50 cc lene con- cals
648-50 tainer • Use to bond high-temperature fit parts.
114E-6 SERIES 50-11

COATING MATERIALS LIST BLY
Liquid gasket
• Use to seal various threaded parts, pipe
Polyethy- joints, and flanges.
LG-5 790-129-9080 1 kg lene con-
tainer • Use to seal taper plugs, elbows, and nip-
ples for hydraulic piping.
• Features: Silicon-based heat and cold-
resistant
LG-6 790-129-9160 200 g Tube • Use to seal flange surface and threaded
parts
• Use to seal oil pan, final drive case, etc.
• Features: Silicon-based quick-curing
sealant
LG-7 790-129-9170 1 kg Tube • Use to seal flywheel housing, intake
manifold, oil pan, thermostat housing,
etc.
LG-8 • Features: Silicon-based heat, vibration,
THREEBOND 419-15-18131 100 g Tube and shock-resistant
1207B • Use to seal transfer case, etc.
• Use for rough surfaces such as the cir-
LG-9 cle gear top seal which is not clamped
THREEBOND 790-129-9310 200 g Tube by bolts, gaps in the weld which must be
1206D
caulked, etc.
• Can be coated with paint.
LG-10 • Use as lubricant or sealant when insert-
THREEBOND 790-129-9320 200 g Tube ing radiator hoses
1206E • Can be coated with paint.
LG-11 • Feature: Can be used together with solid

gaskets.
THREEBOND 790-129-9330 200 g Tube
• Use for covers of the transmission case
1121
and steering case etc.
THREEBOND
790-129-9090 100 g Tube • Liquid gasket used to repair engine
1211
Molybdenum disulfide lubricant

• Use to prevent galling and seizure of
press-fitted parts, shrinkage-fitted parts,
LM-P — 200 g Tube and threaded parts.
• Use to lubricate linkages, bearings, etc.
• Spray type
• Thin molybdenum disulfide films are
made on metal surfaces to prevent the
LM-S — 190 g Pail
metals from galling.
• Use for the drive shaft splines, needle
bearings, various link pins, bolts, etc.
50-12 114E-6 SERIES

BLY COATING MATERIALS LIST
Seizure prevention compound

• Feature: Seizure and galling prevention
compound with metallic super-fine-grain,
LC-G etc.
— — Pail
NEVER-SEEZ • Use for the mounting bolt in the high
temperature area of the exhaust mani-
fold and the turbocharger, etc.
Grease
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
G2-LI SYG2-160LI
• Lithium grease with extreme pressure lu-
G0-LI (*) SY- Various Various brication performance, general purpose
*: For cold dis- GA-160CNLI type.
tricts SYG0-400LI-A
(*)
SYG0-16CNLI
(*)
• Use for parts under heavy load.
Molybdenum Bellows-
• Caution: Do not use this grease for roll-
SYG2-400M 400 gx 10 ing bearings like swing circle bearings,
disulfide type con-
grease SYG2-400M-A 400 gx 20 tainer etc. and spline.
LM-G (G2-M) SYGA-16CNM 16 kg Pail • Caution: Use this grease for work equip-
ment pins only when installing them, but
do not use it afterwards.
Hyper white SYG2-400T-A
grease • Higher seizure resistance, heat resist-
SYG2-16CNT Bellows-
ance, and waterproof than molybdenum
G2-T SYG0-400T-A 400 g type con-
disulfide grease
G0-T(*) (*) 16 kg tainer
Pail
• Not so conspicuous on machine since
*: For cold dis- SYG0-16CNT color is white.
tricts (*)
Biogrease SYG2-400B
G2-B SYGA-16CNB
Bellows- • Since this grease is bacterially biode-
G2-BT (*) SYG2-400BT 400 g type con- gradable in short period, the impact on
*: For use at (*) tainer microorganisms, animals, and plants is
16 kg
high tempera- SY- Pail kept to the minimum.
ture and under GA-16CNBT
high load (*)
• Feature: Silicon-based grease with wider
G2-S operating temperature range and superi-
THREEBOND — 200 g Tube or thermal oxidative stability to prevent
1855
deterioration of rubber and plastic.
• Use for oil seals of the transmission, etc.
114E-6 SERIES 50-13

COATING MATERIALS LIST BLY
• Feature: Urea (organic) grease with heat
resistance and long service life, inclu-
G2-U-SENS sion type.
427-12-11871 2 kg Pail
Grease • Use for rubber, bearing and oil seal in
damper.
• Caution: Do not mix with lithium grease.
Primer
Loctite Glass con- • Use to accelerate hardening of instanta-
428-99-80080 100 mℓ
712 tainer neous adhesive.
SUNSTAR • Use as primer for cab side (Expira-
Glass con-
For adhered window glass

Paint Surface 22M-54–27260 150 mℓ tion date: 4 months after its produc-
tainer
Primer 435-98 tion date)
SUNSTAR • Use as primer for black ceramic-coat-
PRIMER ed glass surface and for hard poly-
22M-54-27240 150 mℓ Steel can
435-41 for carbonate-coated surface (Expiration
glass date: 6 days after its production date)
SUNSTAR • Use as primer for sash (alumite sur-
sash primer 22M-54-27250 900 mℓ Steel can face treatment) (Expiration date:6
GP-402 months after its production date)
Adhesive
Polyethy- • Use as adhesive for glass (Expiration
Sika Japan Si-

20Y-54-39850 310 mℓ lene con- date: 6 months after its production
kaflex 256HV
tainer date)
SUNSTAR Ecocart • Use as adhesive for glass (Expiration
Penguin Super 22M-54-27210 320 mℓ (special date: 6 months after its production
560 container) date)
SUNSTAR Ecocart • Use as adhesive for glass (Expiration
Penguin Seal 416–926–6950 320 mℓ (special date: 6 months after its production
#560 container) date)
Caulking material
SUNSTAR Polyethy- • Use to seal for joint between glasses
Penguin Seal 417-926-3920 320 mℓ lene con- (Expiration date: 4 months after its
No.2505 tainer production date)
Polyethy-
SEKISUI Sili- • Use to seal front window (Expiration
20Y-54-55130 333 mℓ lene con-
cone Sealant date: 6 months after its production)
tainer
GE TOSHIBA • Translucent white seal used for joint
SILICONES 22M-54-27220 333 mℓ Cartridge between glasses (Expiration date: 12
TOSSEAL381 months after its production date)
50-14 114E-6 SERIES

BLY SPECIAL TOOLS LIST
SPECIAL TOOLS LIST

How to read the tool list
• Part Number:
Tools with part number 79*T-***-**** are not supplied (to be locally manufactured).
• Necessity
■: Not substitutable, and work cannot be performed without the tool.
●: Tools extremely useful if available or tools that can be substituted with commercially available tool.
• New/Redesign
N: Tools with new part numbers, newly developed for this model.
R: Tools, with advanced part numbers, developed by improving existing tools for other models.
Blank: Tools already available for other models that can be used without any modification.
• Sketch
○: Tools marked with ○ in the sketch column have the sketches.
Sketches are introduced in “Sketches of special tools”, and all sketches of “79*T-***-***”are described.
New/Redesign
Necessity
Sketch
Q'ty
Symbol Part No. Part name Details of work and remarks
790-501-2001
A Repair stand ■ 1
795-799-1150
Adapter (only for Komatsu re- Disassembly and assembly of engine
790T-901-6030 〇 assembly
pair stand)
B ■ 1
Adapter (only for Cummins re-
795-799-2280
pair stand)
795-102-2103 Removal and installation of intake and
C Spring pusher ● 1
795-799-8800 exhaust valves
D 795-100-2800 Piston ring tool ■ 1 Removal and installation of piston ring

Piston holder (diameter 75 to
E 795-921-1100 ■ 1 Installation of piston
175 mm)
F 795-799-6700 Puller ■ 1 Removal of injector
790-331-1120 Wrench (angle) ● 1
J Angle tightening of bolts
795-799-2240 Angle gauge ● 1
Commercially
K Feeler gauge ● 1 Valve clearance adjustment
available
Commercially Adjustment of gear backlash and end
L Dial gauge and stand ● 1
available play
M 795-799-8150 Remover ● 1 Removal of inlet connector
N 795-799-9300 Lifting tool ● 1 Lifting tool for engine assembly
Removal and installation of supply
P 795-799-1390 Remover ● 1
pump
Removal and installation of cylinder
Q 795-799-8910 Boot pliers ● 1
head valve seal
1 795-799-2170 Liner puller ● 1
R Removal of cylinder liner
2 795-799-2310 Extension ● 1
S 795-799-2110 Cylinder liner driver ● 1 Installation of cylinder liner
114E-6 SERIES 50-15

SPECIAL TOOLS LIST BLY
New/Redesign
Necessity
Sketch
Q'ty
Symbol Part No. Part name Details of work and remarks
T 795-799-8120 Oil seal screwdriver ● 1 Installation of front seal

Removal and installation of main bear-
U 795-799-2270 Remover, installer ● 1
ing
V 795-799-1131 Gear ● 1 Rotation of crankshaft
W 795-799-7110 Torque wrench ● 1 Tightening of injector wiring harness nut
Measurement of cylinder head bolt
X 795-790-2210 Gauge ● 1
length
Y 795-799-2190 Clamp set ● 1 Installation of cylinder liner
Disassembly and assembly of engine
Z - Block ■ 4
assembly
Disconnection of supply pump drive
AA - Bolt (M8x1.25) ● 2
gear
AB - Lock plate ● 1 Removal of flywheel
AC - Eyebolt ● 1 Flywheel lifting tool
AD - Jack bolt ● 1 Removal of cylinder liner
AE - Guide bolt ■ 2 Installation of gasket
AF - Guide pin ■ 1 Installation of rear cover
AG - Guide bolt ■ 1 Installation of flywheel
AH - Guide pin ■ 2 Installation of gasket
AJ - Box-end combination wrench ● 1 Fixing of flywheel and flywheel housing
50-16 114E-6 SERIES

BLY SKETCHES OF SPECIAL TOOLS
SKETCHES OF SPECIAL TOOLS

k Komatsu does not take any responsibility for special tools manufactured according to these sketch-
es.
B: Adapter
114E-6 SERIES 50-17

DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY BLY
ENGINE SYSTEM
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY
NOTICE
• Before starting your work, check the shapes, quantity, locations, etc. of the parts depending on the
machine model.
• Before disassembling the engine, check its parts for cracking, damage, etc. and clean it thoroughly
and carefully for accurate inspection of its parts and quick disassembly and assembly.
• Before cleaning the engine, carefully seal the openings or remove electric parts and wiring connec-
tors so that water does not enter them.
• Clean every parts throughly and check them for dent, scratch and void. Also check that passages of
oil and coolant is not clogged, and then assemble them.
50-18 114E-6 SERIES

BLY DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY
METHOD FOR DISASEMBLING ENGINE GENERALLY
㻭㼠㼠㼍㼏㼔㼙㼑㼚㼠㻌㼠㼛㻌
㻼㼞㼑㼜㼍㼞㼍㼠㼛㼞㼥㻌㻻㼕㼘㻌㼒㼕㼘㼘㼑㼞㻌㼜㼛㼞㼠㼍㼚㻌㼑㼚㼓㼕㼚㻌㼞㼑㼜㼍㼕㼞㻌
㼣㼛㼞㼗㼟㼠㼍㼚㼐
㻲㼡㼑㼘㻌㼒㼕㼘㼠㼑㼞
㻱㼚㼓㼕㼚㼑㻌
㼏㼛㼚㼠㼞㼛㼘㼘㼑㼞
㻱㻳㻾㻌㼢㼍㼕㼢㼡
㻮㼘㼛㼣㼎㼥㻌㼔㼛㼟㼑
㼀㼡㼎㼑㻌㼍㼚㼐㻌㼔㼛㼟㼑㻱㼤㼔㼍㼡㼟㼠㻌
㻷㼂㻳㼀
㼙㼍㼚㼕㼒㼛㼘㼐
㻱㻳㻾㻌㼏㼛㼛㼘㼑㼞
㻿㼠㼍㼞㼠㼕㼚㼓㻌
㼍㼟㼟㼑㼙㼎㼘㼥
㻭㼘㼠㼑㼞㼚㼍㼠㼛㼞㻌㼎㼑㼘㼠
㻭㼘㼠㼑㼞㼚㼍㼠㼛㼞
㻼㼡㼘㼘㼑㼥㻌㼍㼚㼐㻌
㼘㼕㼒㼠㼕㼚㼓㻌㼜㼘㼍㼠㼑
㻮㼑㼘㼠㻌㼠㼑㼚㼟㼕㼛㼚㼑㼞
㼃㼍㼠㼑㼞㻌㼜㼡㼙㼜
114E-6 SERIES 50-19

㼍㼚㻌㼑㼚㼓㼕㼚㼑㻌㼞㼑㼜㼍㼕㼞㻌㼀㼔㼑㼞㼙㼛㼟㼠㼍㼠
㼟㼠㼍㼚㼐
㻯㼛㼛㼘㼍㼚㼠㻌㼕㼚㼘㼑㼠㻌
㼏㼛㼚㼚㼑㼏㼠㼛㼞
㻻㼕㼘㻌㼒㼕㼘㼠㼑㼞㻌㼍㼚㼐㻌㼛㼕㼘㻌
㼏㼛㼛㼘㼑㼞
㻴㼑㼍㼐㻌㼏㼛㼢㼑㼞㻌㼍㼚㼐㻌㻾㼛㼏㼗㼑㼞㻌㼍㼞㼙㻌㼍㼚㼐㻌
㻼㼡㼟㼔㻌㼞㼛㼐
㼞㼛㼏㼗㼑㼞㻌㼔㼛㼡㼟㼕㼚㼓㻌㼏㼞㼛㼟㼟㼔㼑㼍㼐
㻵㼚㼖㼑㼏㼠㼛㼞㻌㻯㼥㼘㼕㼚㼐㼑㼞㻌㼔㼑㼍㼐㻌㻰㼕㼟㼍㼟㼟㼑㼙㼎㼘㼥㻌㼛㼒㻌

㼍㼟㼟㼑㼙㼎㼘㼥㼍㼟㼟㼑㼙㼎㼘㼥㼏㼥㼘㼕㼚㼐㼑㼞㻌㼔㼑㼍㼐㻌
㻵㼚㼠㼍㼗㼑㻌㼙㼍㼚㼕㼒㼛㼘㼐㻌
㻴㼕㼓㼔㻌㼜㼞㼑㼟㼟㼡㼞㼑㻌
㼏㼛㼢㼑㼞
㼜㼕㼜㼑
㻿㼡㼜㼜㼘㼥㻌㼜㼡㼙㼜
㻯㼛㼙㼙㼛㼚㻌㼞㼍㼕㼘㻌㼍㼚㼐㻌
㼏㼛㼚㼚㼑㼏㼠㼛㼞㻌㼎㼘㼛㼏㼗
㻮㼛㼛㼟㼠㻌㼜㼡㼙㼜
50-20 114E-6 SERIES

㻭㼠㼠㼍㼏㼔㼙㼑㼚㼠㻌㼠㼛㻌㼍㼚㻌
㼑㼚㼓㼕㼚㼑㻌㼞㼑㼜㼍㼕㼞㻌㼟㼠㼍㼚㼐
㼂㼕㼎㼞㼍㼠㼕㼛㼚㻌㼐㼍㼙㼜㼑㼞㻲㼞㼛㼚㼠㻌㼛㼕㼘㻌㼟㼑㼍㼘㻱㼚㼓㼕㼚㼑㻌㼒㼞㼛㼚㼠㻌

㻯㼍㼙㼟㼔㼍㼒㼠㼀㼍㼜㼜㼑㼠
㼏㼛㼢㼑㼞
㻻㼕㼘㻌㼜㼡㼙㼜㻳㼑㼍㼞㻌㼟㼔㼍㼒㼠
㻿㼡㼜㼜㼘㼥㻌㼜㼡㼙㼜㻌
㼓㼑㼍㼞
㻯㼥㼘㼕㼚㼐㼑㼞㻌㼘㼕㼚㼑㼞㻯㼥㼘㼕㼚㼐㼑㼞㻌㼎㼘㼛㼏㼗
㻲㼘㼥㼣㼔㼑㼑㼘㻌㻾㼑㼍㼞㻌㼛㼕㼘㻌㼟㼑㼍㼘
㻲㼘㼥㼣㼔㼑㼑㼘㻾㼑㼍㼞㻌㼏㼛㼢㼑㼞
㼔㼛㼡㼟㼕㼚㼓
㻼㼕㼟㼠㼛㼚㻘㼏㼛㼚㼚㼑㼏㼠㼕㻼㼕㼟㼠㼛㼚㻌㼏㼛㼛㼘㼕㼚㼓㻌
㻯㼍㼙㼟㼔㼍㼒㼠㻯㼞㼍㼚㼗㼟㼔㼍㼒㼠
㼚㼓㻌㼞㼛㼐㻌㼍㼟㼟㼑㼙㼎㼘㼥㼚㼛㼦㼦㼘㼑
㻰㼕㼟㼍㼟㼟㼑㼙㼎㼘㼥㻌㼛㼒㻌
㼏㼛㼚㼚㼑㼏㼠㼕㼚㼓㻌㼞㼛㼐㻌
Preparation
1. Set engine assembly (1) on a rigid and stable tool Z.
4 Engine assembly (1):

Approximately 900 kg (The weight varies depend-
ing on the machine model.)
114E-6 SERIES 50-21

Oil filler port

2. Disconnect clamp (2) of oil filler port (1).
3. Loosen hose clamp (3), and remove oil filler port (1).
4. Disconnect tube clamp (4).
5. Remove tube (5).
6. Pull blowby hose (6) while pressing lock (a) to disconnect

blowby hose (6).
7. Remove oil filler port inlet connector (7).
Fuel filter, hose

8. Disconnect fuel hoses (2) and (3) from fuel filter (1).
REMARK
Pry the hose end surface by using a screwdriver, etc. while
pressing the fitting portions (right and left) of the hose end
to disconnect fuel hoses (2) and (3).
9. Disconnect clamp (5) that ties fuel hoses (2), (3) and (4)
together.
10. Disconnect fuel filter (1) together with bracket (6).
50-22 114E-6 SERIES


12. Remove tube (8).
13. Remove fuel hose (2).

Engine controller
17. Remove NE (crankshaft) speed sensor connector (3).
18. Remove engine oil pressure switch connector (4)
19. Remove fuel lift pump connector (5).
20. Remove Bkup (cam) speed sensor connector (6).
21. Remove bolt (7) of wiring harness (2).
22. Remove clamp (8) that is fixing wiring harness (2).
23. Remove clip (10) together with bracket (9).
24. Remove clamp (13) and clip (11) that are fixing wiring har-
ness (2) together with bracket (12).
25. Remove hexagonal socket head bolt (14) (4 mm) of wiring
harness (2).
26. Remove clamp (16) that is fixing wiring harness (2).
REMARK
Wiring harness (2) is tightened together with the clamp of
blowby hose (15).
27. Remove clamp (16a) that is fixing wiring harness (2).
28. Remove connectors J1 (1a) and J2 (1b) from engine con-
troller (1).
29. Remove engine controller (1).
REMARK
Ground cable (17) is tightened together with the engine controller mounting bolt.
114E-6 SERIES 50-23

Engine controller cooling plate, fuel lift pump

30. Remove engine controller cooling plate (2) and bracket (1).
31. Remove fuel lift pump (3) on the back side of engine con-
troller cooling plate (2).
32. Remove ground cable (3) and engine oil pressure switch
connector (4).
EGR valve
33. Disconnect wiring harness connectors (1), (2), and (3).
REMARK
• Connector (1): VGT position sensor
• Connector (2): VGT speed sensor
• Connector (3): Connector box
34. Disconnect hoses (4) and (5).
REMARK
• Hose (4): VGT control hydraulic circuit
• Hose (5): VGT drive hydraulic circuit
50-24 114E-6 SERIES

35. Disconnect clamp (7) of wiring harness (6) from bracket

(8).
36. Disconnect EGR valve piping (9) from EGR valve (10).
NOTICE
Be careful not to drop the gasket.
37. Remove bracket (8) from EGR valve (10).
38. Remove EGR valve (10).
39. Loosen EGR valve piping (9) from hose clamp (11).
Wiring harness assembly

40. Disconnect coolant temperature sensor connector (2).
41. Disconnect wiring harness clamps (6) and (7).
42. Disconnect wiring harness clamps (11), (12) and (13).
114E-6 SERIES 50-25

43. Disconnect ambient pressure sensor connector (14).

44. Disconnect supply pump connector (15).
45. Disconnect wiring harness connectors (16) (3 places).
46. Disconnect band (18).
47. Disconnect charge (boost) pressure and temperature sen-

sor connector (19).
48. Disconnect common rail pressure sensor connector (20).
49. Disconnect wiring harness clamp (21).
50. Disconnect wiring harness bracket (22).
51. Remove the wiring harness assembly.
Intake manifold
52. Disconnect clamp (4) of supply pump connector (5) from
intake manifold (1).
53. Remove intake manifold (1).
Blowby hose
54. Remove blowby hose (1).
50-26 114E-6 SERIES

Installation to engine repair stand

55. Remove dipstick pipe (1).
REMARK
The shape varies depending on the machine model.
56. Install tool B to engine assembly (2).

57. Sling engine assembly (2), and install it to tool A.
4 Engine assembly (2):

Approximately 880 kg (The weight varies depend-
ing on the machine model.)
58. Drain the engine coolant and engine oil.
6 Engine oil:
Approximately 30 ℓ
Tubes and hoses

59. Disconnect hose (1) and tube (2) at portion (a).
61. Loosen hose clamp (4) and remove tube (2).
63. Disconnect tube clamps (6), and remove tube (7).

64. Remove bracket (8).
65. Disconnect hoses (10) and (11) from EGR cooler (9).
114E-6 SERIES 50-27

66. Disconnect hose (14) from VGT (13).

67. Remove bracket (16) and connector block (17) together
with hoses (10), (11), and (14) from exhaust manifold (15).
VGT
68. Loosen hose clamp (1), and disconnect tube (2).
69. Disconnect tube (3).
70. Sling VGT (4), and remove it.
4 VGT:
30 kg
Starting motor assembly

71. Remove mounting bolt (2) and nut (3), and remove starting
motor assembly (1).
50-28 114E-6 SERIES

Alternator belt
72. Remove alternator belt (1).
REMARK
Apply a wrench to portion (b) (width across flats: 12.7 mm)
of auto-tensioner (2). Turn it to the opposite to the winding-
up direction to loosen the tension of alternator belt (1).
k Be sure that the wrench is installed securely to
portion (b) of auto-tensioner (2) before turning it.
(Since the spring force of auto-tensioner (2) is
strong, the wrench may come off and is very dan-
gerous if it is turned when not attached securely.)
k After removing alternator belt (1), return auto-ten-
sioner (2) slowly and carefully.
k Be careful not to get your fingers caught between
the pulley and alternator belt (1) during work.
Alternator
73. Remove alternator (1).
74. Remove brackets (3).
Pulley, slinging plate

75. Remove pulley (1), wiring harness brackets (2) and (3).
76. Remove slinging plate (4).
Auto-tensioner
77. Remove auto-tensioner (1).
114E-6 SERIES 50-29

Thermostat
78. Remove coolant outlet connector (2).
REMARK
79. Remove thermostat (1).
Coolant inlet connector

80. Remove coolant inlet connector (1).
81. Remove plug (2).
Water pump
82. Remove water pump (1).
Oil filter, oil cooler
50-30 114E-6 SERIES

REMARK
Put an oil container under the oil filter and oil cooler during this work.
83. Remove oil filter (1).
84. Remove bolts (6), and remove cover (2) and cover gasket
(3).
85. Remove oil cooler (4) and cooler gasket (5).
EGR cooler
86. Remove mounting bolt (1), and disconnect EGR cooler (2)
and exhaust manifold (3).
REMARK
When disconnecting, be careful not to drop the gasket.
87. Remove bottom side tube (4) of EGR cooler.
88. Remove EGR cooler (2).

91. Remove plugs (7) and (8).
114E-6 SERIES 50-31

Exhaust manifold
93. Remove exhaust manifold (2).
REMARK
When disconnecting, be careful not to drop the gasket.
Head cover and rocker housing

94. Remove head cover (1).
95. Disconnect wiring harness (2) from the injector.

Wiring harness mounting position
Cable color Cylinder No.
a Yellow Right side
1, 3, 5
b Orange Left side
c Red Right side
2, 4, 6
d Brown Left side
96. Remove mounting bolt (3), and remove rocker housing (4).
50-32 114E-6 SERIES

High-pressure pipe
97. Remove fuel spray prevention caps (8) (14 pieces) of high-
pressure pipes (1) to (7).
98. Loosen sandwich clamp (9) of high-pressure pipes (1) to
(7).
99. Loosen the sleeve nut on the common rail side of high-
pressure pipes (1) to (7).
100. Loosen the sleeve nut on the injector side of high-pressure
pipes (1) to (7).
101. Remove the bolt of sandwich clamp (9) mounting bracket
of high-pressure pipes (1) to (7).
102. Remove high-pressure pipes (1) to (7).
REMARK
Remove the high-pressure pipe together with the sandwich
clamp mounting bracket.

Supply pump
107. Remove cap (1) of the front gear cover.
114E-6 SERIES 50-33

108. Remove nut (2) and washer (3).
109. After removing the washer, tighten nut (2) again.

110. Rotate the crankshaft in the normal direction to set mark
(c) of supply pump drive gear (4) to the top, and set No.1
cylinder to the compression top dead center (TDC).
111. Install tool AA.
112. Remove nuts (5) (4 pieces) and bolts (6) and (7), and re-
move bracket (8).
113. Tighten tool AA installed in step 114 alternately, and dis-
connect the supply pump drive shaft from the supply pump
drive gear.
114. Remove tool AA, and then remove supply pump (9).
50-34 114E-6 SERIES

Boost pump
115. Disconnect hose (1) from cylinder block (2).
116. Remove stud bolts (3) (2 pieces), and remove boost pump
(4).
Common rail, connector block

117. Remove mounting bolts (1) and (2), and remove common
rail (3).
118. Remove wiring harness bracket (4).

119. Remove connector block (5).
114E-6 SERIES 50-35

Rocker arm, crosshead

120. Loosen locknut (4), and then loosen adjustment screw (5)
2 or 3 turns so that valve spring tension is not applied to
the rocker arm mounting bolt (1).
121. Remove mounting bolts (1) (12 pieces), and remove rock-
er arm assembly (2).
122. Remove crosshead (3).
REMARK
Write down the mounting positions and hole shapes of por-
tions a and b.
Push rod
123. Remove push rods (1) (12 pieces).
Injector assembly
50-36 114E-6 SERIES

NOTICE
Clean the inlet connector carefully before removing it so that mud, etc. sticking around it does not enter
its hole.
124. Remove retaining nut (1), and remove inlet connectors (2)
(6 pieces).
REMARK
Use tool M to remove the inlet connector.
125. Remove bolt (3) and remove holder (4).
126. Pull up injector (5) by using tool F.
NOTICE
Do not pry the top of the injector to remove it.
114E-6 SERIES 50-37

Intake manifold cover

127. Remove intake manifold cover (1).
REMARK
Remove bracket (2) that was tightened together.
Cylinder head assembly

128. Remove bolts (1) (26 pieces), and remove cylinder head
assembly (2).
4 Cylinder head assembly:

95 kg
Disassembly of cylinder head assembly

129. Compress valve spring (3) by using tool C, and remove
valve collet (4).
50-38 114E-6 SERIES

130. Remove upper seat (5) and valve spring (3).
131. Raise the cylinder head assembly, and pull off valve (6).
REMARK
Put marks on valve (6) so that you can find matching cylin-
der head.
132. Remove valve seals (7-1) and (7-2) at the top of the head
by using tool Q.
REMARK
• Valve seal (7-1): Exhaust valve
• Valve seal (7-2): Intake valve
Front cover
133. Remove vibration damper (1).
114E-6 SERIES 50-39

134. Remove mounting bolts (2) (26 pieces), and remove front
cover (3).
Front oil seal

135. Remove dust seal (6) from front oil seal carrier assembly
(4).
136. Remove front oil seal carrier assembly (4) from front cover
(3).
137. Remove front oil seal (5).
50-40 114E-6 SERIES

Supply pump drive gear

138. Remove supply pump drive gear (1).
Oil pump
139. Remove bolts (1) (4 pieces), and remove oil pump assem-
bly (2).
Oil pan
140. Set the oil pan upward.
141. Remove bolts (1) (32 pieces), and remove oil pan (2).
142. Remove suction tube (3), bracket (4), and bed plate (5).
114E-6 SERIES 50-41

Camshaft
143. Rotate the crankshaft, and align the mark of camshaft gear
assembly (1) with that of camshaft gear (2).
144. Remove bolt (3), and remove thrust plate (4).
145. Remove camshaft gear assembly (1) while rotating it.
Gear housing
146. Remove bolts (1) (5 pieces), and remove gear housing (2).
50-42 114E-6 SERIES

Flywheel
147. Install tool AB, and remove mounting bolt (1).
148. Install tool AC to flywheel (2), sling the flywheel, and re-
move it.
4 Flywheel:
60 kg
Flywheel housing
149. Remove bolts (1) (12 pieces), and remove flywheel hous-
ing (2).
4 Flywheel housing:
60 kg
Rear cover
150. Remove rear cover (1).
114E-6 SERIES 50-43

151. Remove rear oil seal (2).
Piston and connecting rod assembly

152. Rotate the crankshaft so that the piston to be pulled out
comes to the bottom dead center (BDC).
153. Scrub the carbon off the top wall of the liner by using fine
sandpaper.
REMARK
Before removing the piston and connecting rod assembly,
measure the side clearance between the connecting rod
and crankshaft by using tool K.
154. Apply a mark to connecting rod cap (1) and connecting rod
(2) respectively according to the cylinders.
155. Remove bolt (3).
156. Tap connecting rod cap (1) with a plastic hammer, and remove connecting rod cap (1) and connecting rod
bearing as a unit.
NOTICE
Store the connecting rod and connecting rod cap so that their mating faces is not damaged. If their
mating faces are damaged, replace them.
157. Push in the piston and connecting rod assembly by using a
wooden bar, etc. from the oil pan side, and then remove it
from the cylinder head side while supporting piston (4).
NOTICE
• Take care not to damage the inner surface of the
cylinder with a corner of the connecting rod.
• Put the cylinder No. mark on the piston.
158. Remove the other piston and connecting rod assemblies
according to the same procedure.
NOTICE
Take care not to damage the sliding surfaces of the
pistons, bearings, etc.
50-44 114E-6 SERIES

Disassembly of connecting rod assembly

159. Remove snap ring (5).
160. Pull out pin (6), and disconnect piston (4) and connecting
rod (2).
161. Remove the snap ring on the opposite side.
162. Remove piston ring (7) by using tool D.
NOTICE
Store the piston, connecting rod, bearing, piston ring,
and piston pin for each cylinder.
NE (crankshaft) speed sensor connector

163. Remove NE (crankshaft) speed sensor connector (1).
Crankshaft
114E-6 SERIES 50-45

NOTICE
Crankshaft Measure the end play of the crankshaft by us-
ing tool L before removing the crankshaft.
164. Remove mounting bolt (2) of main cap (1).

165. Record the mounting position number on main cap (1).
NOTICE
Check that the embossed letter “ABBTV” on the side
surface (d) of the main cap faces the rear of the cylin-
der block.
166. Insert bolt (2) into the bolt hole of main cap (1), and re-
move the main cap while shaking it.
167. Remove lower main bearing (3) from main cap (1).
NOTICE
Record the position number on the back side of the re-
moved bearing. (Do not use the bearing sliding sur-
face for the record.)
50-46 114E-6 SERIES

168. Sling crankshaft (4), and remove it.
NOTICE
• When slinging and removing the crankshaft, do not
hit it against the cylinder block and damage the
crankshaft.
• Store the crankshaft in a safe place so that its slid-
ing surfaces are not damaged.
4 Crankshaft:
85 kg
169. Remove speed sensor ring (5).
170. Remove upper thrust bearing (6) (1 piece at the center)

and upper bearing (7) (6 pieces).
NOTICE
Mark the installation position on the main cap, upper
bearing, and upper thrust bearing (use the back side
for the bearing), and group them on a cap basis. And
take care not to damage these parts.
Tappet
171. Remove tappets (1) (12 pieces).
114E-6 SERIES 50-47

Piston cooling nozzle

172. Remove bolt (1), and remove piston cooling nozzles (2) (6
pieces).
Cylinder liner
NOTICE
Measure the protrusion of the cylinder liner by using tool L
before removing the cylinder liner.
173. Put a mark (A) on the cylinder liner mounting position, and
insert tool R from the top of the cylinder block.
NOTICE
• Set arm [5] so that it does not contact against sup-
ports [1], [2], [3], and [4] of cylinder liner (1).
• Set tool R at the center of the top of the cylinder
liner.
174. Rotate tool AD clockwise, pull up cylinder liner (1) from cyl-
inder block (2), and remove cylinder liner (1) by both
hands.
NOTICE
Record the mounting position number on the removed
cylinder liner.
50-48 114E-6 SERIES

Cylinder block
175. Sling cylinder block (1), and disconnect it from repair stand
(tool A).
4 Cylinder block:
245 kg
176. Remove tool B from cylinder block (1).
114E-6 SERIES 50-49

METHOD FOR ASEMBLING ENGINE GENERALLY
㼍㼚㻌㼑㼚㼓㼕㼚㼑㻌㼞㼑㼜㼍㼕㼞㻌㻯㼥㼘㼕㼚㼐㼑㼞㻌㼘㼕㼚㼑㼞㼀㼍㼜㼜㼑㼠㻯㼞㼍㼚㼗㼟㼔㼍㼒㼠㻯㼛㼚㼚㼑㼏㼠㼕㼚㼓㻌㼞㼛㼐㻌 A
㼟㼠㼍㼚㼐㼍㼟㼟㼑㼙㼎㼘㼥
㻼㼕㼟㼠㼛㼚㻌㼏㼛㼛㼘㼕㼚㼓㻌
㼚㼛㼦㼦㼘㼑
㻿㼜㼑㼑㼐㻌㼟㼑㼚㼟㼛㼞㻌
㼏㼛㼚㼚㼑㼏㼠㼛㼞㻌㼞㼕㼚㼓
㻲㼞㼛㼚㼠㻌㼓㼑㼍㼞㻌
A 㼔㼛㼡㼟㼕㼚㼓
㻯㼍㼙㼟㼔㼍㼒㼠㻻㼕㼘㻌㼜㼡㼙㼜㻾㼑㼍㼞㻌㼏㼛㼢㼑㼞 B
㻿㼡㼜㼜㼘㼥㻌㼜㼡㼙㼜㻌㻱㼚㼓㼕㼚㼑㻌㼒㼞㼛㼚㼠㻌㻲㼞㼛㼚㼠㻌㼛㼕㼘㻌㼟㼑㼍㼘

B 㼐㼞㼕㼢㼑㻌㼓㼑㼍㼞
㻿㼡㼜㼜㼘㼥㻌㼜㼡㼙㼜
㼏㼛㼢㼑㼞 C
㻲㼘㼥㼣㼔㼑㼑㼘㻌㻾㼑㼙㼛㼢㼍㼘㻌㼒㼞㼛㼙㻌
C 㻻㼕㼘㻌㼜㼍㼚
㼔㼛㼡㼟㼕㼚㼓
㻲㼘㼥㼣㼔㼑㼑㼘㼍㼚㻌㼑㼚㼓㼕㼚㼑㻌㼞㼑㼜㼍㼕㼞㻌
㼟㼠㼍㼚㼐
50-50 114E-6 SERIES

㻾㼑㼙㼛㼢㼍㼘㻌㼒㼞㼛㼙㻌㻯㼥㼘㼕㼚㼐㼑㼞㻌㼔㼑㼍㼐㻌㻵㼚㼠㼍㼗㼑㻌㼙㼍㼚㼕㼒㼛㼘㼐㻌㻵㼚㼖㼑㼏㼠㼛㼞㻌

㼍㼚㻌㼑㼚㼓㼕㼚㼑㻌㼞㼑㼜㼍㼕㼞㻌㼍㼟㼟㼑㼙㼎㼘㼥㼏㼛㼢㼑㼞㼍㼟㼟㼑㼙㼎㼘㼥
㻼㼡㼟㼔㻌㼞㼛㼐 A
㼟㼠㼍㼚㼐
㻺㻱㻔㼏㼞㼍㼚㼗㻕㻌
㼟㼜㼑㼑㼐㻌㼟㼑㼚㼟㼛㼞㻌
㻮㼛㼛㼟㼠㻌㼜㼡㼙㼜
㻯㼛㼛㼘㼍㼚㼠㻌㼕㼚㼘㼑㼠㻌
㻻㼕㼘㻌㼒㼕㼘㼠㼑㼞
㻾㼛㼏㼗㼑㼞㻌㼍㼞㼙㻌㼍㼚㼐㻌㼏㼛㼙㼙㼛㼚㻌㼞㼍㼕㼘㻌㼍㼚㼐㻌㻯㼛㼙㼙㼛㼚㻌㼞㼍㼕㼘㻌

A 㼏㼞㼛㼟㼟㻌㼔㼑㼍㼐㼏㼛㼚㼚㼑㼏㼠㼛㼞㻌㼎㼘㼛㼏㼗㼜㼞㼑㼟㼟㼡㼞㼑㻌㼟㼑㼚㼟㼛㼞
㻴㼕㼓㼔㻌㼜㼞㼑㼟㼟㼡㼞㼑㻌 B
㼜㼕㼜㼑
㻴㼑㼍㼐㻌㼏㼛㼢㼑㼞㻌㼍㼚㼐㻌
㼞㼛㼏㼗㼑㼞㻌㼔㼛㼡㼟㼕㼚㼓
㻱㼤㼔㼍㼡㼟㼠㻌㼀㼡㼎㼑㻌㼍㼚㼐㻌㼔㼛㼟㼑
B 㼙㼍㼚㼕㼒㼛㼘㼐
㻷㼂㻳㼀
㻱㻳㻾㻌㼏㼛㼛㼘㼑㼞
114E-6 SERIES 50-51

㻾㼑㼙㼛㼢㼍㼘㻌㼒㼞㼛㼙㻌㻭㼘㼠㼑㼞㼚㼍㼠㼛㼞㻌㼎㼑㼘㼠
㼍㼚㻌㼑㼚㼓㼕㼚㼑㻌㼞㼑㼜㼍㼕㼞㻌㼃㼍㼠㼑㼞㻌㼜㼡㼙㼜
㼟㼠㼍㼚㼐
㻭㼘㼠㼑㼞㼚㼍㼠㼛㼞
㻮㼑㼘㼠㻌㼠㼑㼚㼟㼕㼛㼚㼑㼞
㻼㼡㼘㼘㼑㼥㻘㼘㼕㼒㼠㼕㼚㼓㻌
㼜㼘㼍㼠㼑
㼂㼕㼎㼞㼍㼠㼕㼛㼚㻌
㼐㼍㼙㼜㼑㼞
㻾㼑㼙㼛㼢㼍㼘㻌㼒㼞㼛㼙㻌㻵㼚㼠㼍㼗㼑㻌㼙㼍㼚㼕㼒㼛㼘㼐㻌
㼍㼚㻌㼑㼚㼓㼕㼚㼑㻌㼞㼑㼜㼍㼕㼞㻌㻴㼍㼞㼚㼑㼟㼟㻌㻱㻳㻾㻌㼢㼍㼘㼢㼑
㼏㼛㼢㼑㼞
㼟㼠㼍㼚㼐㼍㼟㼟㼑㼙㼎㼘㼥
㻱㼚㼓㼕㼚㼑㻌㼏㼛㼚㼠㼞㼛㼘㼘㼑㼞㻌
㼏㼛㼛㼘㼕㼚㼓㻌㼜㼘㼍㼠㼑㻌㼍㼚㼐㻌㻱㼚㼓㼕㼚㼑㻌
㻲㼡㼑㼘㻌㼒㼕㼘㼠㼑㼞
㼒㼡㼑㼘㻌㼘㼕㼒㼠㻌㼜㼡㼙㼜㼏㼛㼚㼠㼞㼛㼘㼘㼑
㻮㼘㼛㼣㼎㼥㻌㼔㼛㼟㼑㻌㼍㼚㼐㻌
㼛㼕㼘㻌㼒㼕㼘㼘㼑㼞㻌㼜㼛㼞㼠
㻱㼚㼓㼕㼚㼑㻌㼛㼕㼘㻌
㼜㼞㼑㼟㼟㼡㼞㼑㻌㼟㼣㼕㼠㼏㼔㻌
㼍㼚㼐㻌㼜㼘㼡㼓
50-52 114E-6 SERIES

Cylinder block
1. Install cylinder block to tool B.
2. Sling cylinder block (1), and install it to repair stand (tool
A).
4 Cylinder block:
245 kg
Cylinder liner
3. Preparation
NOTICE
• Clean the cylinder liner to remove all deposits and
broken pieces from seal surfaces (e), (f) and (g),
and rub the surface with sandpaper, etc. until the
machined surface is exposed before inserting the
cylinder liner. (Be careful not to excessively grind
the surface.)
• Apply clean engine oil to surfaces (e) and (f).
2 Seal surfaces (e) and (f):
Engine oil (EO15W-40)
REMARK
To use the cylinder liner again, install it to the original posi-
tion, rotate the liner 45 ° from the original installation posi-
tion to adjust the installation direction, and then install it.
(Slide the pitch surface of the cylinder liner, and separate it
from the area where pitching occurs.)
4. Apply engine oil to O-ring seal of cylinder liner (1).

REMARK
Slightly apply the oil right before assembling.
5. Install O-ring (3) to cylinder liner (1).
NOTICE
Check that O-ring is not twisted when installing.
114E-6 SERIES 50-53

6. Push cylinder liner (1) into the cylinder block (2) with both
hands.
NOTICE
If the cylinder liner does not enter smoothly, O-ring
may be broken. In this case, check the cylinder block
for existence of “burrs” and “sharp edge”.
7. By using tool S, press-fit cylinder liner (1).
8. By using tool Y and cylinder head installation bolt (4), in-

stall cylinder liner (1).
3 Mounting bolt:
68±10 Nm {6.93±1.02 kgm}
9. After press-fitting the cylinder liner, measure the protrusion

of the cylinder liner at 4 places equally-spaced on circum-
ference by using tool L.
REMARK
Protrusion of cylinder liner: 0.026 to 0.122 mm
10. If protrusion of the cylinder liner exceeds 0.025 mm within
the range of 180 ° on the liner circumference, perform the
work described on steps 8 and 9 again to install it within
the specified dimension range.
Tappet guide pin

11. Install the tappet guide pins (1) (12 pieces) to the cylinder
block.
3 Tappet guide pin (1):
10±1 Nm {1±0.1 kgm}
REMARK
When reusing the tappet guide pin, install it after applying
the liquid adhesive.
2 Tappet guide pin (1):
Liquid adhesive (LT-2)
Tappet
50-54 114E-6 SERIES

NOTICE
• To reuse the tappet, be sure to keep the same combination.
• Do not install the reused tappet to a new camshaft.
• Check that there is no damage on the tappet guide groove (1a) and roller part (1b) when reusing the
tappet. Replace it if there is any damage.
12. Apply engine oil to the tappet.
2 Tappet:
13. Install tappets (1) (12 pieces).

NOTICE
Tappet may be removed from mounting hole when as-
sembling, do not rotate it more than 90 °.
Piston cooling nozzle

14. Install piston cooling nozzle (2) (6 pieces), and tighten it
with bolt (1).
3 Mounting bolt:
27±3 Nm {2.75±0.31 kgm}
Crankshaft
15. Install upper bearings (7) (6 pieces), upper thrust bearing
(6) (1 piece).
114E-6 SERIES 50-55

NOTICE
• Set the protruding portion of the bearing to the notch of the cylinder block for installation.
• Check that foreign material is not attached to the back surface of the bearing before installation.
• Apply engine oil to the inner surface of the bearing. At this time, do not apply engine oil to the
back surface.
• When reusing the bearing, check the mark placed at disassembly, and install it to the original
position.
2 Inner surface of bearing:
16. Install speed sensor ring (5) with new bolts.
NOTICE
• Be sure to tighten new bolts. (Do not reuse them.)
• Tighten bolts alternately from side to side.
3 Mounting bolt:
8±2 Nm {0.82±0.2 kgm}
17. Sling crankshaft (4), and install it.

NOTICE
Be careful not to damage the bearing when installing
it.
4 Crankshaft:
85 kg
18. Install the lower main bearing (3) to main cap (1) while
matching its protrusion to the notch.
NOTICE
Check the installation position number described on
the back side of the bearing.
50-56 114E-6 SERIES

19. Apply engine oil to journal surface of the crankshaft.

2 Journal surface of crankshaft:
20. Check the installation position mark of main cap (1), direct
the embossed letter “ABBTV” of portion (d) toward the rear
of the cylinder block, and then install it.
NOTICE
Push it in by hitting it lightly with a plastic hammer or
rubber hammer.
21. Tighten main cap mounting bolts (2) in the numerical order
([1] to [14]) shown in the figure.
22. Apply engine oil to the bolts.

2 Mounting bolt:
3 1st time:
• Main cap mounting bolt:
50±7 Nm {5.1±0.71 kgm}
3 2nd time:
95±6 Nm {9.69±0.61 kgm}
3 3rd time:
60 ° {±5 °} (Angle tightening tool J is used.)
23. When not using tool J, put marks on the main cap and bolt
with paint, and then retighten the bolts 60±5 °.
114E-6 SERIES 50-57

24. After tightening the bolt, rotate crankshaft (4) to check that
it rotates smoothly.
25. Measure the end play of crankshaft (4) by using tool L.
REMARK
End play: 0.109 to 0.360 mm
Piston, Connecting rod assembly

26. Install piston ring (7) to the piston by using tool D.
27. Fit oil ring (9) so that its abutment joint is 180 ° away from
the end of expander (8).
28. Install second ring (10) directing the punching mark “TOP”
near the abutment joint upward.
29. Install top ring (11) directing the punching mark “dot” near
the abutment joint upward.
30. Install each ring directing the abutment joint to the direc-
tion other than the direction of thrust and opposite direction
of thrust, and axial direction of piston.
31. Apply engine oil to piston ring and piston skirt.
2 Piston ring, piston skirt:
50-58 114E-6 SERIES

32. Apply engine oil to piston pin hole and piston pin.
2 Piston pin hole, piston pin:
33. Insert piston pin (6), and assemble piston (4) to connecting
rod (2).
34. Attach snap rings (5) on both sides.
35. Install bearings (12) to connecting rod (2) and connecting

rod cap (1).
NOTICE
• Check that foreign material is not attached to the
back side of the bearing.
• Install the bearing to the connecting rod and con-
necting rod cap while matching its protrusion to
the notches.
36. Set the crankshaft of the cylinder to be installed at the bot-
tom dead center, and apply engine oil to inner surface of
cylinder.
2 Inner surface of cylinder:
37. Insert piston and connecting rod assembly directing
“FRONT” mark of piston (4) to the front of cylinder block.
NOTICE
• Check the direction of the piston ring abutment
joint again.
• Be careful not to damage the cylinder wall when in-
serting the connecting rod.
• Be careful not to hit the piston cooling nozzle when
installing it.
• Compress the piston rings by using tool E, and
push in the piston head with a wood bar, etc.
114E-6 SERIES 50-59

38. Tighten connecting rod cap (2) with bolt (1) according to
the following procedure.
39. Apply engine oil to the threaded portion of the bolt and the
inner surface of connecting rod bearing.
2 Inner surface of connecting rod bearing:
Mounting bolts (Tighten both bolts alternately.)
3 1st time:
30±5 Nm {3.06±0.51 kgm}
3 2nd time:
50±5 Nm {5.1±0.51 kgm}
3 3rd time:
60±5 ° (Angle tightening tool J is used.)
40. When not using tool J, put marks on the cap and bolt with
paint, and then retighten the bolts 60±5 °.
41. Check that crankshaft rotates smoothly without any abnor-

mality after installing piston and connecting rod assembly.
42. Measure the end play between connecting rod and crank-
shaft by using tool K.
REMARK
Side clearance: 0.130 to 0.275 mm
50-60 114E-6 SERIES

Front gear housing

43. Install tool AE, and install gasket (1).
REMARK
Gasket extrusion from oil pan mounting face: Max.
0.25 mm
44. Install gear housing (2).

REMARK
• Lightly tighten the gear housing with the bolt, and then
remove the guide bolts.
• Tighten the bolts in the numerical order ([1] to [5])
shown in the figure.
3 Mounting bolt:
40±2.0 Nm {4.08±0.20 kgm}
Camshaft
45. Apply engine oil to camshaft bore, camshaft journal, and
lobe surface. Push camshaft gear assembly (1) lightly, and
install it while rotating.
NOTICE
• Rotate the crankshaft so that No.1 cylinder comes
to top dead center (TDC).
• Install camshaft while taking care not to damage
the cam bushing.
2 Camshaft sliding surface:
46. Align the timing mark of camshaft gear assembly (1) with
that of crankshaft gear (2).
114E-6 SERIES 50-61

47. Install thrust plate (4) with bolt (3).

3 Mounting bolt:
24±4 Nm {2.45±0.41 kgm}
48. Measure the end play of camshaft gear assembly (1) by

using tool L.
REMARK
• The amount of end play is determined by thickness of
thrust plate and groove of camshaft.
• End play: 0.10 to 0.36 mm
49. Measure the backlash of camshaft gear assembly (1) by

using tool L.
REMARK
Backlash: 0.075 to 0.325 mm
Oil pump
50. Fill the space in the pump rotor and the idler shaft bore
with engine oil, and rotate them 2 turns.
2 Space in the pump rotor and idler shaft bore:
50-62 114E-6 SERIES

51. Lightly tighten oil pump assembly (2) with bolt (1).
NOTICE
Securely insert oil pump idler shaft (3) to the position-
ing hole of the cylinder block.
52. Tighten oil pump mounting bolts (2) in the numerical order
Mounting bolt:
3 1st time:
15±1 Nm {1.53±0.1 kgm}
3 2nd time:
24±4 Nm {2.45±0.41 kgm}
53. Measure backlash (k) of the oil pump and idler gear when
rotating the crankshaft 1 turn.
REMARK
Backlash: 0.205±0.125 mm
114E-6 SERIES 50-63

Water pump
54. Install water pump (1).
3 Mounting bolt:
24±4 Nm {2.45±0.41 kgm}
Supply pump gear

55. Align the timing mark “0” of camshaft gear assembly (1)
with the timing mark “00” of supply pump gear (2), and
then install it.
REMARK
Rotate the crankshaft in the normal direction to set stamp
line (a) of the supply pump gear to the top, and set No.1
and No.6 cylinders to the top dead center (TDC).
Supply pump
56. Before installing the supply pump, check dowel pin (1) of
the supply pump drive shaft for a damage.
NOTICE
If the dowel pin is damaged, replace the supply pump
and supply pump gear.
57. Fit brand-new O-ring (2) to the flange of the supply pump.
2 O-ring (2):
58. Fit brand-new O-ring (3) to the lubrication port of the sup-
ply pump.
59. Clean the periphery surface of the supply pump drive shaft
and the inside contact surface of the supply pump gear by
using contact cleaner.
60. Before installing the supply pump, check that the periphery
surface of the supply pump drive shaft and the inside con-
tact surface of the supply pump gear are free from foreign
material and they are dry.
50-64 114E-6 SERIES

61. Align dowel pin (1) of supply pump drive shaft (5) with key-
way (b) of supply pump gear (4), and push in it.
62. Install the washer (6) to the supply pump drive shaft (5),
and tighten the nut (7) lightly.
63. Tighten the mounting nut (9) lightly to a degree that it is not
loosened, and fix the supply pump (8).
2 Mounting nut (9):
REMARK
Tighten the mounting bolt on the cylinder head side and
mounting bolt on the supply pump flange side after instal-
ling the cylinder head.
64. Tighten the supply pump mounting nut (9).
3 Mounting nut (9):
43±6 Nm {4.38±0.61 kgm}
65. Tighten the nut (7).
3 Nut (7):
180±13 Nm {18.4±1.33 kgm}
114E-6 SERIES 50-65

Front oil seal

66. Set front oil seal (8) from pilot (8a) side to tool T.
NOTICE
Since pilot (8a) is a plastic part on the inside of the
front oil seal and a guide tool for installation of the
crankshaft, do not remove it from the front oil seal.
67. Install front oil seal (8) from inside of front oil seal carrier
(7).
NOTICE
The installation height of the front oil seal must be the
same as that of the inner flat surface of the front oil
seal carrier.
68. Apply and push pilot (8a) into the crankshaft together with
front oil seal carrier (7) by hands.
69. Remove pilot (8a).
70. Apply the liquid gasket to all internal periphery (a) of front
oil seal carrier (7).
71. Apply liquid gasket to thread portion (b) of bolt (9) and
front oil seal carrier contact surface (c).
72. Apply liquid gasket to thread portion (d) of nut (10).
2 (a), (b), (c), and (d) in figure:
Liquid gasket (LG-7)
73. Install front oil seal carrier (7).
74. Tighten mounting nuts (10) of front oil seal carrier (7) in the
numerical order ([1] to [5]) shown in the figure.
3 Mounting nut:
8±1 Nm {0.82±0.1 kgm}
Engine front cover
50-66 114E-6 SERIES

NOTICE
• Check that crankshaft end surface corners and lip sliding surfaces are free from scratch, burrs,
sharp edge, rust, etc.
• Do not apply oil or grease to the crankshaft and seal lip. Also, wipe off oil or grease thoroughly from
the crankshaft.
75. Install cover (5) with mounting bolts (6).
2 Cover mounting face:
76. Tighten the bolts in the numerical order ([1] to [26]) shown
in the figure.
Bolt position Bolt size Tightening torque
1, 5, 8, 10, 16, 17, 19, 30±2 Nm
M8x1.25-25
20, 22, 23 {3.06±0.2 kgm}
M8x1.25-35 30±2 Nm
2
(Stud bolt) {3.06±0.2 kgm}
M8x1.25-25 30±2 Nm
4, 7, 13
(Stud bolt) {3.06±0.2 kgm}
3, 6, 9, 11, 12, 14, 15, 40±2 Nm

M8x1.25-25
18, 21, 24, 25, 26 {4.08±0.2 kgm}
77. Install dust seal (9).
REMARK
Push in it until it hits the oil seal.
Rear oil seal

78. Apply neutral detergent to the periphery of the rear oil seal.
NOTICE
Since plastic part (2a) on the inside of the rear oil seal
is a pilot (guide tool) for installation of the crankshaft,
do not remove it from the rear oil seal.
114E-6 SERIES 50-67

79. Install rear oil seal (2) to rear cover (1).
80. By using alignment tool (positioning tool) (2b) of the rear

oil seal accessories, push in rear oil seal (2) into rear cover
(1) until it reaches the proper depth.
81. Remove alignment tool (2b).
Rear cover
82. Clean, degrease, and dry the gasket surfaces of the rear
cover and cylinder block.
83. Clean the seal lip surfaces (surfaces around crankshaft) to
remove foreign materials. Then, degrease and dry the sur-
faces.
NOTICE
Check that crankshaft end surface corners and lip slid-
ing surfaces are free from scratch, burrs, sharp edge,
rust, etc.
84. After installing tool AF and gasket (3), apply pilot (2a) to
crankshaft (4), and push in the pilot together with rear cov-
er (1) into crankshaft (4) by hands.
2 Housing mounting face:
86. Adjust the height of rear cover (1) as the same as those of
both sides (m) of the oil pan rail.
REMARK
• Horizontal direction: Max. 0.00±0.10 mm
• Vertical direction: Max. 0.150 mm
50-68 114E-6 SERIES

87. Install alignment tool (2b) again, and check that rear oil
seal (2) is pushed in to a proper depth.
NOTICE
Leave alignment tool (2b) installed. Do not remove it.
88. Remove the guide pin, and tighten the mounting bolts in
the numerical order ([1] to [8]) shown in the figure.
3 Mounting bolt:
13±2 Nm {1.33±0.2 kgm}
90. Measure the facial runout and radial runout of the rear oil
seal against the crankshaft.
REMARK
• Facial runout: Max. 0.38 mm
• Radial runout: Max. 0.25 mm
91. Install seal (5) to seal cover (1).
92. Cut off the extruded parts of gasket (3) (right and left).
REMARK
• Protrusion from under surface of cylinder block: Max.
0.24 mm
• Be careful not to drop the gasket that was cut off into
the engine.
Oil pan
93. Apply liquid gasket to the clearance (marked with ▲) be-
tween the cylinder block and gear housing and between
cylinder block and rear cover.
2 Clearance (marked with ▲):
114E-6 SERIES 50-69

94. Apply tool AH to cylinder block (1), and install gasket (2).
95. Install bed plate (3).

96. Insert the gasket to the tip flange surface, and install suc-
tion tube (4).
2 Flange:
3 Flange mounting bolt:
10±2 Nm {1.02±0.2 kgm}
97. Apply liquid gasket to the hatched section of the mating

face on the bed plate side, and install gasket (5).
2 Gasket (bed plate mating face):
50-70 114E-6 SERIES

98. Apply liquid gasket to the periphery of the mating face on

the gasket side of oil pan (6).
2 Oil pan:
99. Install oil pan (6) with mounting bolt (7).

100. Tighten oil pan mounting bolts (7) in the numerical order
3 Mounting bolt:
28±4 Nm {2.86±0.41 kgm}
Flywheel housing
101. Apply a bead of liquid gasket 1 to 3 mm in diameter to the
mounting flange surface of the flywheel housing and the
area around the mounting bolt holes.
2 Mounting flange surface and the area around
mounting bolt:
102. Sling flywheel housing (1), and install it with the bolt.
4 Flywheel housing:
60 kg
114E-6 SERIES 50-71

103. Tighten flywheel housing mounting bolts (2) in the numeri-

cal order ([1] to [12]) shown in the figure.
3 Mounting bolt:
77±12 Nm {7.85±1.22 kgm}
Measurement of radial runout

104. Set tool L to the end surface of crankshaft.
105. Apply the probe of the dial gauge perpendicular to the spi-
got joint portion of the flywheel housing.
106. Set the dial gauge pointer to “0”, rotate the crankshaft by 1
turn, and measure the difference between the lowest and
the highest values of the pointer of dial gauge points.
REMARK
• When the crankshaft is rotated by 1 turn, check that the
dial gauge indicates the same value as it of the starting
rotation.
Measurement of facial runout
107. Similarly to measurement of the radial runout, set the
probe of the dial gauge perpendicular to the end face of
the flywheel housing.
REMARK
When measuring, move the crankshaft to either end of
front or rear to eliminate error caused by the end play.
REMARK
Facial runout: Max. 0.20 mm
Flywheel
109. Install tool AG, and install flywheel (1).
REMARK
Apply a bead of liquid gasket 1 to 3 mm in diameter to the
area around the bolt hole (8 places) of the mounting face
with the crankshaft.
2 Flywheel mounting face:
4 Flywheel:
60 kg
110. Install tool AB.
50-72 114E-6 SERIES

111. Tighten the mounting bolts in the numerical order ([1] to

[8]) shown in the figure.
3 Mounting bolt:
137±7 Nm {14.0±0.71 kgm}

112. Set tool L to the flywheel housing.
113. Set the probe of the dial gauge at a right angle to the spi-
got joint portion (a) or outside of the flywheel.
114. Rotate the flywheel 1 turn, and measure the difference be-
tween the lowest and the highest values of the pointer of
dial gauge points.
REMARK
• When the flywheel rotated 1 turn, check that the dial
gauge indicates the same value as it of the starting ro-
tation.
115. Similarly to the measurement of radial runout, set the dial gauge so that its probe is at a right angle with the
end face (b) near the periphery of the flywheel.
NOTICE
When measuring, move the crankshaft to either end of front or rear to eliminate error caused by the
end play.
116. Rotate the flywheel 1 turn, and measure the difference between the lowest and the highest values of the
pointer of dial gauge points.
REMARK
Cylinder head assembly
117. Install valve seals (7-1) and (7-2).
REMARK
• Exhaust valve: (7-1)
• Intake valve: (7-2)
114E-6 SERIES 50-73

118. Apply engine oil to the valve stem and the inside of the
valve guide, and install valve (6).
2 Inner surfaces of valve stem and valve guide:
119. Raise the cylinder head, and install valve spring (3) and
upper seat (5).
120. By using tool C, compress valve spring (3) and install

valve collet (4).
REMARK
Check that the collet is fitted securely to the groove of the
valve stem by hitting the valve stem part lightly with a plas-
tic hammer.
121. Measure the stem length (a) of every mounting bolt and
check that it is within the using limit.
REMARK
Allowable limit of bolt length: less than: 162.6 mm.
NOTICE
Do not reuse the bolt whose length exceeds the using
limit. Replace it.
50-74 114E-6 SERIES

122. Check that the cylinder head mounting face and inside of
the cylinder are free from “dirt” or “foreign matter”, and in-
stall cylinder head gasket (8) to cylinder block (1).
REMARK
Check that the holes of the gasket is fitted to those of the
cylinder block.
123. Install cylinder head assembly (2) to cylinder block (1).
4 Cylinder head assembly:

95 kg
124. Apply engine oil to the threaded portion of bolts and to the
seat surface of the bolt head.
2 Threaded portion of bolt and seat surface of bolt
head:
REMARK
Screw in the mounting bolt 2 to 3 turns or more at first by
hand to tighten it.
Cylinder head mounting bolt:
3 1st time:
50±7 Nm {5.1±0.71 kgm}
3 2nd time:
150±10 Nm {15.3±1.02 kgm}
3 3rd time: Return all the bolts by:
360 °.
3 4th time:
115±5 Nm {11.7±0.51 kgm}
3 5th time: Check:
115±5 Nm {11.7±0.51 kgm} .
3 6th time:
120±5 ° (tightened by angle tightening tool J)
114E-6 SERIES 50-75

REMARK
When not using an angle tightening tool J, put a mark on
cylinder head and bolt with paint, and retighten bolt
120±5 °.
125. Lightly tighten bracket (12) on cylinder head (2) with bolts
(10) and (11).
126. Tighten mounting bolt (10) on the cylinder head side.
3 Mounting bolt (10):

65 Nm {6.63 kgm}
127. Tighten mounting bolt (11) on the flange side of supply
pump (9).
80 Nm {8.16 kgm}
Intake manifold cover

128. Apply liquid gasket to cylinder head (4), and install gasket
(3).
2 Both sides of gasket:
129. Install intake manifold cover (1) and bracket (2).
3 Mounting bolt:
24±4 Nm {2.45±0.41 kgm}
REMARK
Some bolts are tightened when installing the high-pressure
pipes. (All bolts are not tightened.)
50-76 114E-6 SERIES

Injector assembly
130. Check that the injector sleeve is free from scratches and
dirt.
131. When replacing the injector with a new one, replace inlet
connector (11) with a new one, as well.
REMARK
• In case of burrs, wear or scratches found on tip end (a)
and rear edge (b) of the inlet connector, replace inlet
connector (11).
• If foreign materials are attached to the edge filter at
rear edge (c) of the inlet connector, replace inlet con-
nector (11).
• If O-ring at top (d) of the inlet connector is cracked or
deteriorated, replace inlet connector (11).
• If seat surface (e) at the tip of the inlet connector is
worn or the seat surface unevenly hits, replace inlet
connector (11).
NOTICE
If high-pressure fuel leaks through the inlet connector,
seat surface is eroded and has fine streaks or cracks.
When this phenomenon is detected, replace the inlet
connector and injector.
132. Install gasket (12) and O-ring (13) to the injector (7).
133. Apply engine oil to O-ring of injector (7) and the head side.
2 O-ring of injector (7) and head side:

134. Insert injector (7) into the cylinder head while directing its
fuel inlet hole toward intake manifold.
114E-6 SERIES 50-77

135. Install holder (6) and screw in bolts (5) 3 to 4 turns by fin-
gers.
136. Screw in the bolt (5) 3 to 4 turns by finger-tightening.
137. Install the holder (6) and screw in the bolt (5) 3 to 4 turns
by finger-tightening.
138. Apply engine oil to O-ring and the mounting hole on the
head side of inlet connector (11).
2 O-ring of inlet connector and head side:
139. Apply the liquid gasket (f) to Inlet connector (hatched sec-
tion).
2 Inlet connector (hatched area):
140. Tighten inlet connector (11) lightly with retaining nut (10).
NOTICE
After tightening each of them lightly, tighten it to the
specified torque. If tightening torque is insufficient or
too much, it will cause fuel leakage inside the engine.
3 Retaining nut:
17.5±2.5 Nm {1.78±0.25 kgm}
141. Tighten mounting bolts (5) alternately so that the top of
holder (6) is parallel to the top of the cylinder head.
3 Bolt:
10±2 Nm {1.02±0.2 kgm}
REMARK
Maximum allowable angle2.4 °
142. Tighten inlet connector (11) with the retaining nut to the
specified torque.
3 Retaining nut (10) (tightening to the specified tor-
que):
50±4 Nm {5.1±0.41 kgm}
Push rod
143. Pour engine oil to push rod socket part.
2 Push rod socket portion:

50-78 114E-6 SERIES

144. Install push rod (1).
NOTICE
Check that the push rod is fitted to the tappet.
Rocker arm and crosshead

145. Install crosshead (3).
146. Install rocker arm assembly (2), and tighten it with bolt (1).
NOTICE
Check that the spherical part of adjustment screw (5)
is fitted properly in the socket of push rod (4), and
tighten the mounting bolt.
3 Mounting bolt:
65±5 Nm {6.63±0.51 kgm}
NOTICE
Shape of holes in (a) and (b) portions of crosshead is
not identical. So when reusing them for the same in-
take or exhaust valve, be sure to install them in the
same direction.
REMARK
A brand-new crosshead can be installed in any direction.
Adjusting valve clearance

147. As for the valve clearance (when cooling down the machine), adjust the clearance between the crosshead
and rocker arm to the following values.
• Intake valve: 0.30±0.08 mm
• Exhaust valve: 0.56±0.08 mm
148. Rotate the crankshaft in the normal direction to set stamp
line (a) of supply pump gear (1) to the top, and set No.1
114E-6 SERIES 50-79

149. While the No.1 cylinder is at the compression top dead

center, adjust the valve clearance marked with ● in the
valve layout drawing.
150. Insert tool K between rocker arm (2) and crosshead (3),
and fix adjustment screw (4) to a degree that the screw
moves lightly.
151. Tighten lock nut (5) at this position.
3 Locknut:
24±2.4 Nm {2.45±0.24 kgm}
REMARK
After tightening lock nut (7), and check the valve clearance
again.
152. After finishing the adjustment of all the valves marked with
●, rotate the crankshaft in the normal direction again to set
stamp line (a) of supply pump gear (1) to the bottom, and
set No.6 cylinder to the compression top dead center
(TDC).
153. While the No.6 cylinder is at the compression top dead
center, adjust the valve clearance marked with ○ in the
valve layout drawing.
REMARK
Adjustment procedure is the same as steps 145 and 146.
154. After adjusting clearance of all valves, install cap (6).
50-80 114E-6 SERIES

NE (crankshaft) speed sensor connector

155. Install NE (crankshaft) speed sensor connector (1).
3 Mounting bolt:
9±2 Nm {0.92±0.2 kgm}
Replacement of common rail pressure sensor and pressure limiter

NOTICE
• Do not remove common rail pressure sensor (2) from common rail (1) for a purpose other than re-
placement.
• Be sure to replace the common rail pressure sensor removed from the common rail with a new sen-
sor.
156. Before removing the common rail pressure sensor, clean
the area around it, and remove dirt, etc. thoroughly.
157. Remove the common rail pressure sensor.
158. Check the common rail pressure sensor connector for
crack, breakage, damage of the seal, foreign material on
the pin and corrosion, bend and breakage of the pin.
159. Apply gear oil to the threaded portion of the new common
rail pressure sensor and threaded portion of the adapter
2 Threaded portion of common rail pressure sensor:
Gear oil (#90)
2 Threaded portion of adapter:
Gear oil (#90)
160. Install a new common rail pressure sensor.
3 Common rail pressure sensor:

70±5 Nm {7.14±0.51 kgm}
3 Adapter:
37±4 Nm {3.77±0.41 kgm}
161. Thoroughly remove dirt and dusts on and around the pressure limiter before removing it.
162. Remove the pressure limiter.
163. Do not reuse the pressure limiter if leakage exceeds the
specified value.
164. Check that there is no damage on high-pressure sealing
surfaces (A) on the pressure limiter and common rail.
165. Apply gear oil to threaded portion of the new pressure lim-
iter.
2 Threaded portion of pressure limiter:
Gear oil (#90)
166. Install a new pressure limiter.
3 Pressure limiter:
100±4 Nm {10.2±0.41 kgm}
114E-6 SERIES 50-81

NOTICE
Excessive tightening can cause leakage. Take care not to tighten excessively.
167. Check that adapter (4) is not damaged.
REMARK
If adapter (4) was removed, use a brand-new copper seal washer (5), apply gear oil (#90) to the adapter,
and tighten it.
3 Adapter:
37±4 Nm {3.77±0.41 kgm}
2 Copper seal washer (5):
Gear oil (#90)
Common rail, high-pressure pipe, connector block
NOTICE
• Do not bend high-pressure pipe to correct before us-
ing.
• Be sure to use the Komatsu genuine high-pressure
pipe fixing clamps and observe the specified tightening
torque.
• Install each high-pressure pipe and wiring harness at
least 10 mm apart from each other.
REMARK
A high-pressure pipe must be replaced if dents such as
slits (b) or spots (c) are visually recognizable in taper seal
part (a) (2 mm from the tip) of its connection, or if level dif-
ference in part (d) (within 2 mm from taper seal end face)
due to fatigue is large enough to catch your finger nails
because such high-pressure pipe can induce fuel leakage.
168. Lightly tighten common rail (16) with mounting bolts (17)
and (18). (Finger-tightening)
169. Install high-pressure pipe (7) between supply pump and

common rail together with high-pressure pipe (2), and
tighten bracket lightly.
3 Sleeve nut:
37±4 Nm {3.77±0.41 kgm}
170. Lightly tighten brackets of high-pressure pipes (2) and (5)
between common rail and injector.
171. Install high-pressure pipes (1), (2), (3), (4), (5), and (6).
3 Sleeve nut:
37±4 Nm {3.77±0.41 kgm}
172. Tighten common rail (16) to the specified torque.
50-82 114E-6 SERIES

3 Mounting bolt:
43±4.0 Nm {4.38±0.41 kgm}
173. Tighten brackets of high-pressure pipes (2), (5), and (7).
3 Mounting bolt:
24±4 Nm {2.45±0.41 kgm}
174. Install fuel spray prevention caps (8) (14 pieces).
NOTICE
• Direct slits of fuel spray prevention caps outward and downward.
• The fuel spray prevention caps are installed so that fuel will not spout over the hot part of the
engine and catch fire when it leaks by any chance.
175. Install connector block (10).
3 Mounting bolt:
24±4 Nm {2.45±0.41 kgm}
176. Install wiring harness connector bracket (11).
3 Mounting nut:
24±4 Nm {2.45±0.41 kgm}
177. Install tube (12) (supply pump and center of centralized

block).
3 Joint bolt:
24±4 Nm {2.45±0.41 kgm}
3 Tube clamp mounting bolt (15):
43±6 Nm {4.38±0.61 kgm}
178. Install tube (13) (common rail pressure limiter and L.H. of
centralized block).
3 Joint bolt:
24±4 Nm {2.45±0.41 kgm}
179. Install tube (14) (cylinder head and R.H. of centralized block).
3 Joint bolt:
24±4 Nm {2.45±0.41 kgm}
114E-6 SERIES 50-83

Rocker housing and head cover

180. Install the gasket to rocker housing (1).
181. Install rocker housing (1) to cylinder head (2).
182. Tighten the mounting bolts in the numerical order ([1] to
3 Mounting bolt:
24±4 Nm {2.4±0.4 kgm}
183. When injector wiring harness connector (7) was removed,
install it to rocker housing (1).
3 Injector wiring harness connector:
10±2 Nm {0.51±0.1 kgm}
184. Tighten wiring harness (4) to injector (3).
3 Mounting nut:
5±1 Nm {0.13±0.03 kgm}
Installed positions of wiring harnesses
Cable color Cylinder No.
a Yellow Right side
1, 3, 5
b Orange Left side
c Red Right side
2, 4, 6
d Brown Left side
50-84 114E-6 SERIES

REMARK
• Install injector wiring harness terminals (5) in a direc-
tion that does not interfere with the rocker arm (6)
when the rocker arm moves.
• Install wiring harness (4) so that it does not touch the

inner wall of rocker housing (1) strongly, does not dis-
engage from guide (8), or is not bent forcibly.
• Secure clearance (p) of at least 3 mm between wiring
harness (4) and rocker housing (1).
• Secure clearance (r) of at least 3 mm between wiring
harness (4) and rocker arm (6).
185. Install the gasket to head cover (9), and install head cover
(9) to rocker housing (1).
3 Head cover mounting bolt:
12±2 Nm {1.22±0.2 kgm}
114E-6 SERIES 50-85

186. Install slinging plate (10) to cylinder head (2).
3 Mounting bolt:
77±12 Nm {7.85±1.22 kgm}
Boost pump
187. Install gasket, and install boost pump (4) with mounting
bolts (3) (2 pieces).
3 Mounting bolt:
77±12 Nm {7.85±1.22 kgm}
188. Install hose (1) to cylinder block (2).
3 Sleeve nut:
24±4 Nm {2.45±0.41 kgm}
Thermostat, coolant outlet connector

189. Install the gasket, and install thermostat (1).
190. Install coolant outlet connector (2).
REMARK
3 Mounting bolt:
24±4 Nm {2.45±0.41 kgm}
50-86 114E-6 SERIES

Coolant inlet connector

191. Install coolant inlet connector (1).
3 Mounting bolt:
24±4 Nm {2.45±0.41 kgm}
192. Install plug (2).
3 Plug:
85±8 Nm {8.67±0.82 kgm}
EGR cooler, exhaust manifold

193. Install plugs (4) and (5).
3 Plug (4):
115±12 Nm {11.7±1.22 kgm}
3 Plug (5):
75±8 Nm {7.7±0.8 kgm}
194. Install EGR cooler mount bracket (3).
3 Mounting bolt:
43±6 Nm {4.38±0.61 kgm}
195. Install a brand-new gasket, and install exhaust manifold (1)

with bolt (6).
196. Tighten mounting bolts (6) in the numerical order ([1] to

53±6 Nm {5.4±0.61 kgm}
197. Tighten mounting bolts (6) in the numerical order ([1] to [4])
shown in the figure.
53±6 Nm {5.4±0.61 kgm}
114E-6 SERIES 50-87

198. Install EGR coolers (2) to exhaust manifold (1) and EGR
mount bracket (3), and finger-tighten them.
199. Tighten mounting bolts (7) of EGR cooler (2) and exhaust
manifold (1).
3 Mounting bolt:
43±6 Nm {4.38±0.61 kgm}
200. Tighten mounting bolts (8) of EGR cooler (2) and EGR
mount bracket (3).
201. Install tube (9) to EGR cooler (2).
3 Mounting bolt:
9.5±2 Nm {0.97±0.2 kgm}
3 Tube clamp:
8.8±0.5 Nm {0.9±0.05 kgm}
Starting motor assembly
202. Apply a bead of liquid gasket (s) 1 mm in diameter to the
gasket.
2 Both sides of gasket:
203. Install the gasket, and install starting motor assembly (1)
with bolts (2) and nuts (3).
VGT
204. Install tube (4).
50-88 114E-6 SERIES

205. Install a brand-new gasket (2) to exhaust manifold (3).
206. Sling VGT (1) and install it while inserting it into the hose
of tube (4).
4 VGT:
30 kg
207. Install mounting nuts (5) (4 pieces) of VGT (1).
REMARK
Install one (5a) of the mounting nuts to the bottom side.
3 VGT mounting nut:
55±6 Nm {5.61±0.61 kgm}
3 Hose clamp:
5±1 Nm {0.51±0.1 kgm}
208. Install bracket (7).
REMARK
Since two pieces of the mounting bolts must be tightened
together with the sensor bracket, install them after instal-
ling the sensor bracket.
3 Mounting bolt:
43±6 Nm {4.38±0.61 kgm}
209. Lightly tighten tube (8) to bracket (7).
210. Install the gasket, and install tube (8) to EGR cooler (9).
3 Mounting bolt:
24±4 Nm {2.45±0.41 kgm}
211. Tighten tube (8) to bracket (7) to the specified torque.
3 Mounting bolt:
43±6 Nm {4.38±0.61 kgm}
114E-6 SERIES 50-89

212. When connector block (11) was disconnected from bracket

(10) during disassembly, install connector block (11) and
bracket (10).
3 Mounting bolt:
24±4 Nm {2.45±0.41 kgm}
213. Install bracket (10) to which connector block (11), hoses
(12), (13) and (14) are installed to exhaust manifold (3).
3 Mounting bolt:
43±6 Nm {4.38±0.61 kgm}
214. Install hoses (12) and (13) to EGR cooler (9).
3 Sleeve nut:
15±1 Nm {1.53±0.1 kgm}
215. Install gasket, and install hose (14) to VGT (1).
3 Joint bolt:
40±4 Nm {4.08±0.41 kgm}
216. When hose (14) was disconnected from connector block
(11), install hose (14) to connector block (11).
3 Sleeve nut:
36±4 Nm {3.67±0.41 kgm}
Oil cooler, oil filter, tubes

217. Install cooler gasket (5) and oil cooler (4).
218. Install cover gasket (3) and oil cooler cover (2) with bolt
(6).
219. Tighten the bolts in the numerical order ([1] to [11]) shown
in the figure.
Mounting bolt:
3 1st time:
15±4 Nm {1.53±0.41 kgm}
3 2nd time:
27±4 Nm {2.75±0.41 kgm}
50-90 114E-6 SERIES

220. Install tube (9) to plug (7) and EGR cooler (8).
3 Hose clamp (10):

5±1 Nm {0.51±0.1 kgm}
3 Mounting nut (oil pump bracket) (11):
10±2 Nm {1.02±0.2 kgm}
3 Mounting bolt (bracket on EGR cooler side) (12):
24±4 Nm {2.45±0.41 kgm}
221. Install hose (13) to tube (9).
3 Sleeve nut:
35±5 Nm {3.57±0.51 kgm}
222. Install tube (14) to oil cooler cover (2).
3 Sleeve nut:
36±4 Nm {3.67±0.41 kgm}
223. Install tube (17) to VGT (15) and plug (16) installed to cyl-
inder block.
3 Joint bolt (VGT side):
40±5 Nm {4.08±0.51 kgm}
3 Sleeve nut (cylinder block side):
35±5 Nm {3.57±0.51 kgm}
224. Apply engine oil to the oil filter seal.
2 Oil filter seal:

225. Add clean engine oil to the oil filter.
2 Oil filter:
226. Install oil filter (1).
3 Oil filter:
13±2 Nm {1.33±0.2 kgm}
REMARK
Tighten 3/4 turn from contact of the seal surface.
114E-6 SERIES 50-91

Alternator
3 Mounting bolt:
43±6 Nm {4.38±0.61 kgm}
228. Lightly tighten bracket (3).
229. Install alternator (1) to brackets (2) and (3).

98 to 123 Nm {9.99 to 12.5 kgm}
43±6 Nm {4.38±0.61 kgm}
98 to 123 Nm {9.99 to 12.5 kgm}
auto-tensioner
230. Install auto-tensioner (2) with mounting bolt (1).

43±6 Nm {4.38±0.61 kgm}
Pulley, slinging plate

231. Install slinging plate (4) with mounting bolts (5) (3 pieces).
3 Mounting bolt:
43±6 Nm {4.38±0.61 kgm}
232. Install wiring harness bracket (3).
3 Mounting bolt:
43±6 Nm {4.38±0.61 kgm}
50-92 114E-6 SERIES

Vibration damper
233. Install vibration damper (1).
3 Mounting bolt:
200±10 Nm {20.4±1.02 kgm}
Removal from engine repair stand

234. Sling engine assembly (2), and disconnect it from tool A.
4 Engine assembly:
Approximately 880 kg
REMARK
The weight depends on the applicable machine model.
235. Remove tool B from engine assembly (2).
236. Place engine assembly (2) on stabilized tool Z, and fix it.
237. Apply liquid adhesive to the guide of dipstick pipe (1), and
drive in it.
2 Installed portion of dipstick pipe tube.:
Adhesive (LT-4)
114E-6 SERIES 50-93

Engine oil pressure switch connector, plug

238. Install engine oil pressure switch (1) to the cylinder block.
3 Engine oil pressure switch connector:

18±3 Nm {1.84±0.31 kgm}
Intake manifold (intake cover)

239. Install a brand-new gasket (4) to intake manifold cover (5).
240. When intake air heater (2) and intake connector (3) were
removed from intake manifold (1), install air intake connec-
tor (3), gasket (7), intake air heater (2), gasket (7), plate
(8), gasket (7) and intake manifold (1) in this order.
241. Tighten it together with the bracket with mounting bolts.
3 Mounting bolt:
24±4 Nm {2.45±0.41 kgm}
242. Install intake manifold (intake cover) (1).
3 Mounting bolt:
24±4 Nm {2.45±0.41 kgm}
50-94 114E-6 SERIES

Wiring harness assembly

243. Install coolant temperature sensor connector (2).
244. Install bands (5), (8), and (9).

245. Install wiring harness clamps (6) and (7).
3 Mounting bolts (6) and (7):

24±4 Nm {2.45±0.41 kgm}
246. Install wiring harness clamps (11), (12), and (13).
3 Mounting nuts (11), (12), and (13):

10±2 Nm {1.02±0.2 kgm}
247. Install ambient pressure sensor connector (14) and supply

pump connector (15).
248. Install wiring harness connectors (16) (3 places).
249. Install band (18).

24±4 Nm {2.45±0.41 kgm}
114E-6 SERIES 50-95

250. Install charge (boost) pressure and temperature sensor

connector (19), and common rail pressure sensor connec-
tor (20).
251. Install wiring harness clamp (21) and wiring harness brack-
et (22).
10±2 Nm {1.02±0.2 kgm}
24±4 Nm {2.45±0.41 kgm}
252. Install the wiring harness assembly.
EGR valve
253. Install the gaskets to intake manifold (2), and install EGR
valve (1).
3 Mounting bolt:
43±6 Nm {4.38±0.61 kgm}
254. Install the hose of EGR valve piping (3) to tube (4).
255. Install the gasket, and install EGR valve piping (3) to EGR
valve (1).
3 Mounting bolt:
24±4 Nm {2.45±0.41 kgm}
256. Install bracket (5) to the stud bolt.
3 Mounting nut:
24±4 Nm {2.45±0.41 kgm}
257. Fasten hose clamp (6) to the specified torque.
3 Hose clamp:
10.5±0.5 Nm {1.07±0.05 kgm}
258. Install wiring harness (7) to bracket (5).
259. Install hoses (9) and (10) from VGT to EGR valve (1).
REMARK
• Hose (9): VGT control hydraulic circuit
• Hose (10): VGT drive hydraulic circuit
3 Sleeve nuts (hose (9)):
25±1.5 Nm {2.55±0.15 kgm}
3 Sleeve nuts (hose (10)):
15±1 Nm {1.53±0.1 kgm}
260. Install wiring harness connectors (11), (12), and (13) to
EGR valve (1).
50-96 114E-6 SERIES

REMARK
• Connector (11): VGT position sensor
• Connector (12): VGT speed sensor
• Connector (13): Connector box
Fuel lift pump, engine controller cooling plate
261. Install fuel lift pump (3) to engine controller cooling plate
(2).
3 Mounting bolt:
10±2 Nm {1.02±0.2 kgm}
262. Check that valve (4) of the check valve moves smoothly
when lightly pressing it in the direction of an arrow and that
the seal surface is securely closed.
263. Install engine controller cooling plate (2) and bracket (1).
3 Bracket mounting bolt:

43±6 Nm {4.38±0.61 kgm}
Engine controller
264. Install engine controller (1) to engine controller cooling
plate (2) with mounting bolt (3).
3 Mounting bolt:
24±4 Nm {2.45±0.41 kgm}
265. Secure the clearance, and install ground cable (4) to en-
gine controller (1).
3 Mounting nut:
24±4 Nm {2.45±0.41 kgm}
114E-6 SERIES 50-97

266. Install wiring harness (5) to engine controller (1) with hex-
agonal socket head bolts (7) and (4 mm).
3 Mounting bolt:
9±1 Nm {0.92±0.1 kgm}
267. Install connectors J1 (1a) and J2 (1b) to engine controller
(1).
268. Fix wiring harness (5) with bolt (8).

24±4 Nm {2.45±0.41 kgm}
269. Install wiring harness (5) to brackets (9).
270. Install clamp (6).
271. Install NE (crankshaft) speed sensor connector (10).
272. Install engine oil pressure switch connector (11).
273. Install clamp (12) that is fixing wiring harness (5).
3 Mounting bolt:
24±4 Nm {2.45±0.41 kgm}
274. Install clip (12a) that is fixing wiring harness (5).
275. Install clamp (14) that is fixing wiring harness (5) together
with bracket (13).
3 Mounting bolt (clamp (14)):
24±4 Nm {2.45±0.41 kgm}
3 Mounting bolt (bracket (15)):
43±6 Nm {4.38±0.61 kgm}
276. Install fuel lift pump connector (16).
277. Install Bkup (cam) speed sensor connector (17).
Fuel filter, hose
278. Install bracket (8) with bolt (9).
3 Mounting bolt:
43±6 Nm {4.38±0.61 kgm}
50-98 114E-6 SERIES

279. Install fuel hose (4).

283. Install bracket (5), and tie fuel hoses (2), (3) and (4) to-
gether.
3 Mounting bolt:
43±6 Nm {4.38±0.61 kgm}
284. Install fuel filter (1) together with bracket (6).

285. Install fuel hoses (2) and (3) to fuel filter (1).
Blowby hose, oil filler port

286. Install blowby hose (1).
287. Install hose clamps (3) and (4).
REMARK
Install them so that the wiring harness clamp faces out-
ward.
3 Mounting bolt:
24±4 Nm {2.45±0.41 kgm}
288. Install oil filler port inlet connector (2).

289. Install blowby hose (1) to oil filler port inlet connector (2).
REMARK
Insert it until lock (a) clicks.
290. Fasten hose clamp (5).
291. Install tube (6) between EGR valve and boost pump.
3 Sleeve nut:
25±1.5 Nm {2.55±0.15 kgm}
292. Install tube clamps (7) (3 places).
3 Mounting bolt:
24±4 Nm {2.45±0.41 kgm}
114E-6 SERIES 50-99

293. Install tube (8) between EGR valve and oil filler port inlet
connector.
3 Sleeve nut:
25±1.5 Nm {2.55±0.15 kgm}
294. Install tube clamps (9) (3 places).
3 Mounting bolt:
24±4 Nm {2.45±0.41 kgm}
295. Install oil filler port (10) to oil filler port inlet connector (2),
and fasten tube clamp (11).
296. Fasten hose clamp (12) of oil filler port (10).
3 Mounting bolt:
4.5±0.5 Nm {0.46±0.05 kgm}
Alternator belt
297. Install alternator belt (1).
REMARK
Apply a wrench to portion (b) (width across flats: 12.7 mm)
of auto-tensioner (2), and turn it in the winding direction.
portion (b) of auto-tensioner (2) before turning it.
k After installing alternator belt (1), return auto-ten-
REMARK
Check that the clearance between wiring harness (3) and alternator belt (1) is Min. 15 mm.
Sensor tightening torque
298. When removing and installing the sensor, or replacing it, tighten it to the following torque.
Sensor name Tightening torque

Coolant temperature sensor 18±3 Nm {1.84±0.31 kgm}
Engine oil pressure switch 18±3 Nm {1.84±0.31 kgm}
NE (crankshaft) speed sensor 9±2 Nm {0.92±0.2 kgm}
Bkup (cam) speed sensor 9±2 Nm {0.92±0.2 kgm}
Ambient pressure sensor 8±2 Nm {0.82±0.2 kgm}
Charge (Boost) pressure and temperature sensor 3±1 Nm {0.31±0.1 kgm}
Fuel sensor 10±2 Nm {1.02±0.2 kgm}
Fuel sensor bracket 43±6 Nm {4.38±0.61 kgm}
50-100 114E-6 SERIES

Check for fuel leakage

REMARK
• When fuel supply pump (1), common rail (2), and fuel
high-pressure pipe was removed or installed, check for
fuel leakage according to the following procedure after
assembling the engine.
• Clean the engine and the parts around it, and degrease
them in advance so that you can check it easily for fuel
leakage.
299. Spray color checker (developer) to the supply pump, com-
mon rail, injectors, and joints of the high-pressure pipe.
300. Start the engine, keep its speed at 1000 rpm or below, and stop it when the speed is stabilized.
301. Check the fuel piping and component for fuel leakage.
REMARK
• Check the high-pressure circuit for fuel leakage focusing on the area where the color checker is
sprayed.
• If any fuel leakage is detected, repair it and perform the checks from step 299 again.
302. Start the engine, and keep it running at low idle.
REMARK
sprayed.
304. Start the engine, and keep it running at high idle.
REMARK
sprayed.
306. Start the engine and keep it running at high idle, and apply a load to the engine.
REMARK
When checking the engine for leakage as it is installed on the machine, stall the torque converter or relieve
the main pump.
REMARK
sprayed.
• If no fuel leakage is detected, check is complete.
114E-6 SERIES 50-101

REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY BLY
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY

METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY
㻼㼡㼙㼜㻌㼜㼕㼜㼕㼚㼓㻌㻿㼡㼜㼜㼘㼥㼜㼡㼙㼜㻌㻿㼡㼜㼜㼘㼥㻌㼜㼡㼙㼜㻌

㼍㼚㼐㻌㼒㼡㼑㼘㻌㼠㼡㼎㼑㼐㼞㼕㼢㼑㻌㼓㼑㼍㼞㼍㼟㼟㼑㼙㼎㼘㼥
Wiring harness connector

1. Disconnect harness connector (1).
2. Disconnect wiring harness clamp (2).
Pump piping, fuel tube

3. Disconnect fuel hoses (4), (5) and (6) from supply pump
(3).
4. Remove fuel spray prevention cap (7).
5. Remove mounting bolt of bracket (9).
6. Remove high-pressure pipe (10) together with bracket (9).
7. Disconnect tube (11) from supply pump (3).
8. Remove cap (12) of the front gear cover.
50-102 114E-6 SERIES

BLY REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY
Supply pump drive gear

9. Remove nut (13) and washer (14).
10. After removing the washer, tighten nut (13) again.

(a) of supply pump drive gear (15) to the top, and set No.1
12. Install tool P with bolts (15a) (M8 x 1.25).
Supply pump assembly

13. Remove nuts (16) (4 pieces) and bolts (17) and (18), and
remove bracket (19).
14. Tighten bolt (15a) of tool P installed in step 12 alternately,
and disconnect the supply pump drive shaft from the sup-
ply pump drive gear.
15. Remove tool P, and then remove supply pump (3).
114E-6 SERIES 50-103

METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY
㻿㼡㼜㼜㼘㼥㻌㼜㼡㼙㼜㻌㻿㼡㼜㼜㼘㼥㻌㼜㼡㼙㼜㻌㻼㼡㼙㼜㻌㼜㼕㼜㼕㼚㼓㻌

㼍㼟㼟㼑㼙㼎㼘㼥㼐㼞㼕㼢㼑㻌㼓㼑㼍㼞㼍㼚㼐㻌㼒㼡㼑㼘㻌㼠㼡㼎㼑
Supply pump gear

(a) of supply pump drive gear to the top, and set No.1 cyl-
inder to the compression top dead center (TDC).
2. Before installing the supply pump, check dowel pin (20) of

the supply pump drive shaft for a damage.
REMARK
If the dowel pin is damaged, replace the supply pump and
supply pump gear.
3. Fit brand-new O-ring (21) to the flange of the supply pump.

2 O-ring (21):
4. Fit brand-new O-ring (22) to the lubrication port of the sup-
ply pump.
5. Clean the periphery surface of the supply pump drive shaft
and the inside contact surface of the supply pump gear by
using contact cleaner.
6. Before installing the supply pump, check that the periphery
surface of the supply pump drive shaft and the inside con-
tact surface of the supply pump gear are free from foreign
material and they are dry.
50-104 114E-6 SERIES

7. Align dowel pin (20) of supply pump drive shaft (23) with
keyway (b) of supply pump gear (15), and push in it.
8. Fit washer (14) to supply pump drive shaft (23) and tighten
nut (13) lightly.
Supply pump assembly

9. Lightly tighten nut (16) to a degree that it is not loosened to
fix supply pump (3).
2 Mounting nut (16):
10. Tighten supply pump mounting nut (16).
3 Mounting nut (16):
43±6 Nm {4.38±0.61 kgm}
11. Lightly install bracket (19) with bolts (17) and (18).
12. Tighten mounting bolt (17) on the cylinder head side.
65 Nm {6.63 kgm}
13. Tighten mounting bolt (18) on the supply pump flange side.
80 Nm {8.16 kgm}
14. Tighten nut (13).
3 Mounting nut:
180±13 Nm {18.4±1.33 kgm}
114E-6 SERIES 50-105

15. Install cap (12) of the front gear cover.
Pump piping, fuel tube

NOTICE
• Do not bend high-pressure pipe to correct before in-
stalling.
• Be sure to use the Komatsu genuine high-pressure
pipe clamps and observe the specified tightening tor-
que.
• Install each high-pressure pipe and wiring harness at
least 10 mm apart from each other.
• A high-pressure pipe must be replaced if dents such as
slits (b) or spots (c) are visually recognizable in taper
seal part (a) (2 mm from the tip) of its connection, or if
level difference in part (d) (within 2 mm from taper seal
end face) due to fatigue is large enough to catch your
finger nails because such high-pressure pipe can induce fuel leakage.
16. Install high-pressure pipe (10) between the supply pump
and common rail.
3 Sleeve nut:
37±4 Nm {3.77±0.41 kgm}
3 Mounting bolt:
24±4 Nm {2.45±0.41 kgm}
18. Install fuel spray prevention caps (7) (2 pieces).
NOTICE
• Direct slits of fuel spray prevention caps outward
and downward.
• The fuel spray prevention caps are installed so that
fuel will not spout over the hot part of the engine
and catch fire when it leaks by any chance.
19. Install tube (11).
3 Joint bolt:
24±4 Nm {2.45±0.41 kgm}
20. Install fuel hoses (4), (5), and (6) to supply pump assembly (3).
50-106 114E-6 SERIES

Wiring harness connector

21. Install wiring harness clamp (2).
3 Mounting bolt:
24±4 Nm {2.45±0.41 kgm}
22. Install harness connector (1).
114E-6 SERIES 50-107

REMOVE AND INSTALL ENGINE FRONT OIL SEAL BLY
REMOVE AND INSTALL ENGINE FRONT OIL SEAL

METHOD FOR REMOVING ENGINE FRONT OIL SEAL
㻭㼘㼠㼑㼞㼚㼍㼠㼛㼞㻌㼎㼑㼘㼠㻱㼚㼓㼕㼚㼑㻌㼒㼞㼛㼚㼠㻌㼛㼕㼘㻌
㻰㼍㼙㼜㼑㼞
㼟㼑㼍㼘
Alternator belt
1. Remove alternator belt (1).
REMARK
Apply a wrench to portion (a) (width across flats: 12.7 mm)
of auto-tensioner (2). Turn it to the opposite to the winding-
up direction to decrease the tension of alternator belt (1).
portion (a) of auto-tensioner (2) before turning it.
k After removing alternator belt (1), return auto-ten-
Damper
2. Remove bolts (4) (5 pieces), and remove vibration damper
(3).
50-108 114E-6 SERIES

BLY REMOVE AND INSTALL ENGINE FRONT OIL SEAL
Engine front oil seal

3. Remove dust seal (6) from front oil seal carrier assembly
(7).
4. Remove front oil seal carrier assembly (7) from front cover
(5).
5. Remove front oil seal (8).
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL
㻱㼚㼓㼕㼚㼑㻌㼒㼞㼛㼚㼠㻌㼛㼕㼘㻌㻭㼘㼠㼑㼞㼚㼍㼠㼛㼞㻌㼎㼑㼘㼠
㻰㼍㼙㼜㼑㼞
㼟㼑㼍㼘
114E-6 SERIES 50-109

REMOVE AND INSTALL ENGINE FRONT OIL SEAL BLY
Engine front oil seal

1. Wipe off foreign materials sticking to crankshaft flange (A)
with a clean cloth.
2. Set tool T from pilot (8a) side to front oil seal (8).
NOTICE
Since pilot (8a) is a plastic part on the inside of the
front seal and a guide tool for installation of the crank-
shaft, do not remove it from the front oil seal.
3. Install front oil seal (8) from inside of front oil seal carrier
(7).
4. Apply and push pilot (8a) into the crankshaft together with
front oil seal carrier (7) by hands.
6. Apply the liquid gasket to all internal periphery (a) of front

oil seal carrier (7).
7. Apply liquid gasket to thread portion (b) of bolt (9) and
front oil seal carrier contact surface (c).
8. Apply liquid gasket to thread portion (d) of nut (10).
2 (a), (b), (c), and (d) in figure:
9. Install front oil seal carrier (7).
10. Tighten mounting nuts (10) of front oil seal carrier (7) in the
numerical order ([1] to [5]) shown in the figure.
3 Mounting nut:
8±1 Nm {0.82±0.1 kgm}
11. Install dust seal (6).
REMARK
Push in the dust seal until it touches the front oil seal.
50-110 114E-6 SERIES

BLY REMOVE AND INSTALL ENGINE FRONT OIL SEAL
Damper
12. Install vibration damper (1).
200±10 Nm {20.4±1.02 kgm}
Alternator belt
13. Install alternator belt (1).
REMARK
Apply a wrench to portion (a) (width across flats: 12.7 mm)
of auto-tensioner (2), and turn it in the winding direction.
portion (a) of auto-tensioner (2) before turning it.
k After installing alternator belt (1), return auto-ten-
NOTICE
Check that the clearance between wiring harness (3) and alternator belt (1) is Min. 15 mm.
114E-6 SERIES 50-111

REMOVE AND INSTALL ENGINE REAR OIL SEAL BLY
REMOVE AND INSTALL ENGINE REAR OIL SEAL

METHOD FOR REMOVING ENGINE REAR OIL SEAL
㻱㼚㼓㼕㼚㼑㻌㼞㼑㼍㼞㻌㼛㼕㼘㻌
㻲㼘㼥㼣㼔㼑㼑㼘
㼟㼑㼍㼘
Flywheel
1. Remove mounting bolts (2), set the guide bolt, sling fly-
wheel (1), and remove it.
4 Flywheel assembly:
60 kg
2. Sling flywheel housing (4), remove mounting bolt (3), sling

flywheel housing (4), and remove it.
60 kg
Engine rear oil seal

3. Remove oil pan mounting bolts (5) (4 pieces) and housing
mounting bolts (8) (8 pieces), and remove the rear cover
(6).
NOTICE
• When separating the rear cover from the oil pan
gasket, take extreme care not to damage the gas-
ket.
• Insert a feeler gauge, etc. between the rear cover
and the oil pan gasket, and move it back and forth
to separate the gasket.
• If the gasket of the oil pan is damaged, remove the
oil pan and replace the gasket.
6 Engine oil:
approximately 30 ℓ
50-112 114E-6 SERIES

BLY REMOVE AND INSTALL ENGINE REAR OIL SEAL
4. Remove seal (11) from rear cover (6).

5. Remove rear oil seal (7) from rear cover (6).
METHOD FOR INSTALLING ENGINE REAR OIL SEAL
㻱㼚㼓㼕㼚㼑㻌㼞㼑㼍㼞㻌㼛㼕㼘㻌
㻲㼘㼥㼣㼔㼑㼑㼘
㼟㼑㼍㼘
Engine rear oil seal

1. Clean, degrease, and dry the gasket surfaces of the rear
cover and cylinder block.
2. Clean the seal lip surfaces (surfaces around crankshaft) to
remove foreign materials. Then, degrease and dry the sur-
faces.
REMARK
Check that crankshaft end surface corners and lip sliding
surfaces are free from scratch, burrs, sharp edge, rust, etc.
3. Apply neutral detergent to the periphery of the rear oil seal.

NOTICE
Since plastic part (7a) on the inside of the rear oil seal
is a pilot (guide tool) for installation of the crankshaft,
do not remove it from the rear oil seal.
114E-6 SERIES 50-113

4. Install rear oil seal (7) to rear cover (6).
5. By using alignment tool (positioning tool) (7b) of the engine

rear seal accessories, push in rear oil seal (7) into rear
cover (6) until it reaches the proper depth.
7. Apply liquid gasket to thick line area in the figure on the

under surface of rear cover (6).
REMARK
Apply a bead of liquid gasket 3 mm in diameter to thick line
area.
2 Rear cover under surface:
8. Apply liquid gasket thickly to hatched areas (c) (2 places)

in the figure.
2 Hatched area (c):
9. After installing tool AF and gasket (10), apply pilot (7a) to

crankshaft (9), and push in the pilot together with rear cov-
er (6) into crankshaft (9) by hands.
50-114 114E-6 SERIES

REMARK
• Cut gasket (10) so that protrusion (d) toward the oil pan surface is 0.24 mm.
• Be careful not to drop the gasket that was cut off into the engine.
• Adjust the height of rear cover (1) as the same as those of both sides of the oil pan rail.
• Horizontal direction: Max. 0.00±0.10 mm
• Vertical direction: Max. 0.150 mm
11. Install alignment tool (7b) again, and check that rear oil
seal (7) is pushed in to a proper depth.
REMARK
Leave alignment tool (7b) installed. Do not remove it.
12. Lightly tighten oil pan mounting bolts (5).
13. Remove tool AF installed in step 9, and tighten rear cover

mounting bolts (8) (8 pieces) in the numerical order ([1] to
3 Mounting bolt:
13±2 Nm {1.33±0.2 kgm}
14. Tighten oil pan mounting bolts (5) to the specified torque.
3 Mounting bolt:
24±4 Nm {2.45±0.41 kgm}
16. Measure the facial runout and radial runout of the rear oil
seal against the crankshaft.
REMARK
• Facial runout: Max. 0.38 mm
17. Install seal (11) to seal cover (6).
114E-6 SERIES 50-115

Flywheel
mounting flange surface of the flywheel housing and
around the mounting bolt holes.
19. Lightly tighten flywheel housing (4) with mounting bolt (3).
4 Flywheel housing:
60 kg
20. Tighten flywheel housing mounting bolts (3) in the numeri-
cal order ([1] to [12]) shown in the figure.
3 Mounting bolt:
77±12 Nm {7.85±1.22 kgm}
21. Set tool L to the end surface of crankshaft.
22. Apply the probe of the dial gauge perpendicular to the spi-
got joint portion of the flywheel housing.
REMARK
• When the crankshaft is rotated by 1 turn, check that the
dial gauge indicates the same value as it of the starting
rotation.
24. Similarly to measurement of the radial runout, set the
probe of the dial gauge perpendicular to the end face of
the flywheel housing.
REMARK
When measuring, move the crankshaft to either end of
front or rear to eliminate error caused by the end play.
REMARK
Set the facial runout to: Max. 0.20 mm.
area around the bolt hole (8 places) of the mounting face
with the crankshaft.
2 Flywheel mounting face:
27. Install the guide bolt, and install flywheel (1).
4 Flywheel:
60 kg
50-116 114E-6 SERIES

28. Fix the flywheel and flywheel housing by using the lock
plate, tool AJ, etc., and tighten them in the numerical order
3 Mounting bolt:
137±7 Nm {14.0±0.71 kgm}

29. Set tool L to the flywheel housing.
30. Set the probe of the dial gauge at a right angle to the spi-
got joint portion (a) or periphery surface of the flywheel.
31. Rotate the flywheel 1 turn, and measure the difference be-
tween the lowest and the highest values of the pointer of
dial gauge points.
REMARK
• When the flywheel rotated 1 turn, check that the dial
gauge indicates the same value as it of the starting ro-
tation.
32. Similarly to the measurement of radial runout, set the dial gauge so that its probe is at a right angle with the
end face (b) near the periphery surface of the flywheel.
REMARK
When measuring, move the crankshaft to either end of front or rear to eliminate error caused by the end
play.
33. Rotate the flywheel 1 turn, and measure the difference between the lowest and the highest values of the
pointer of dial gauge points.
REMARK
34. While slinging flywheel (1), install it with mounting bolt (2).
60 kg
Oil pan
114E-6 SERIES 50-117

REMARK
When the oil pan was removed to replace the gasket, install the oil pan in the following procedure.
35. Apply liquid gasket to the clearance (marked with ▲) be-
tween the cylinder block and gear housing and between
cylinder block and rear cover.
2 Clearance (marked with ▲):
36. Apply tool AH to cylinder block (12), and install gasket

(13).
37. Install bed plate (14).

38. Insert the gasket to the tip flange surface, and install suc-
tion tube (15).
2 Flange:
3 Flange mounting bolt:
10±2 Nm {1.02±0.2 kgm}
50-118 114E-6 SERIES

39. Apply liquid gasket to the hatched section of the mating

face on the bed plate side, and install gasket (16).
2 Gasket (bed plate mating face):
40. Apply liquid gasket to the periphery of the mating face on

the gasket side of oil pan (17).
2 Oil pan:
41. Install oil pan assembly (17) with mounting bolt (5).
114E-6 SERIES 50-119

42. Tighten oil pan mounting bolts (5) in the numerical order
3 Mounting bolt:
28±4 Nm {2.86±0.4 kgm}
50-120 114E-6 SERIES

60 MAINTENANCE STANDARD
114E-6 SERIES 60-1

CONTENTS 60 MAINTENANCE STANDARD
CONTENTS
ENGINE SYSTEM ......................................................................................................................................... 60-9
INTAKE AND EXHAUST SYSTEM PARTS ............................................................................................. 60-9
MAINTENANCE STANDARD OF VGT............................................................................................. 60-9
ENGINE MAIN BODY PARTS............................................................................................................... 60-10
MAINTENANCE STANDARD OF CYLINDER HEAD ..................................................................... 60-10
MAINTENANCE STANDARD OF CYLINDER BLOCK ................................................................... 60-12
MAINTENANCE STANDARD OF CYLINDER LINER..................................................................... 60-14
MAINTENANCE STANDARD OF CRANKSHAFT .......................................................................... 60-16
MAINTENANCE STANDARD OF PISTON..................................................................................... 60-18
MAINTENANCE STANDARD OF CONROD .................................................................................. 60-19
MAINTENANCE STANDARD OF VIBRATION DAMPER ............................................................... 60-21
MAINTENANCE STANDARD OF TIMING GEAR........................................................................... 60-22
MAINTENANCE STANDARD OF CAMSHAFT .............................................................................. 60-23
MAINTENANCE STANDARD OF VALVE AND VALVE GUIDE....................................................... 60-24
MAINTENANCE STANDARD OF ROCKER ARM .......................................................................... 60-26
MAINTENANCE STANDARD OF FLYWHEEL ............................................................................... 60-27
LUBRICATION SYSTEM....................................................................................................................... 60-29
MAINTENANCE STANDARD OF ENGINE OIL PUMP .................................................................. 60-29
60-2 114E-6 SERIES

60 MAINTENANCE STANDARD ABBREVIATION LIST
ABBREVIATION LIST
the meaning.
Abbrevia-
tion
component/system)
AISS Engine
System speed.
AJSS
Automatic Retarder
the downhill.
ASR
faces.
BCV
used.
Regulator
used independently.
Closed-center Load
Sensing System
114E-6 SERIES 60-3

ABBREVIATION LIST 60 MAINTENANCE STANDARD

Abbrevia-
tion
component/system)
jector.
EGR Engine
emission of NOx.
tional Control
Structure
Forward-Neutral-Re-
verse
Communication
Plus)
Communication
Plus)
HSS
60-4 114E-6 SERIES


Abbrevia-
tion
component/system)
and communication.
Unit
trol motions.
IMA)
KCCV Engine
filters.

KCSF Engine
KDOC Engine
fler.
late Filter
assembled.
LIN
LVDS
MAF sensor.
114E-6 SERIES 60-5


Abbrevia-
tion
component/system)
Service
system
system
Open-center Load
Sensing System
load.
PCCS
pedals, and dials.
Hydraulic system
(D, PC, etc)
ROPS Cab and canopy
ISO 12117-2.
SCR Urea SCR system
devices.
60-6 114E-6 SERIES


Abbrevia-
tion
component/system)
Structure
tion of flow.
VGT Engine
VHPC Engine control
achieved.

D: Bulldozer
HD: Dump truck
WA: Wheel loader
A/C Air Conditioner
A/M Air Mix Damper
ACC Accessory
ADD Additional
AUX Auxiliary
BR Battery Relay
CW Clockwise
ENG Engine
F.G. Frame Ground
GND Ground
NC No Connection
114E-6 SERIES 60-7


S/T
Steering
STRG
SIG Signal
SOL Solenoid
STD Standard
OPT
Option
OP
PRESS Pressure
SPEC Specification
SW Switch
TEMP Temperature
T/M Transmission
60-8 114E-6 SERIES

60 MAINTENANCE STANDARD INTAKE AND EXHAUST SYSTEM PARTS
ENGINE SYSTEM
INTAKE AND EXHAUST SYSTEM PARTS
MAINTENANCE STANDARD OF VGT
Unit: mm
No. Item Criteria Remedy
When compressor wheel and turbine wheel are moved lightly
1 Radial play with the fingers toward the housing, both of them must not touch
the housing.
Replace VGT
2 End play (axial play) 0.025 to 0.127 assembly (in-
cluding hy-
Perform active regeneration for service. At this time, if KDOC in-
draulic actuator
let temperature remains at approximately 250 °C or below and
Operation check of VGT and VGT posi-
VGT solenoid current remains at approximately 1000 mA or be-
3 (Operation check of nozzle tion sensor)
low, VGT is defective. (Approximate time taken for manual sta-
ring)
tionary regeneration depends on accumulation of soot. See fail-
ure code CA2639.)
114E-6 SERIES 60-9

ENGINE MAIN BODY PARTS 60 MAINTENANCE STANDARD
ENGINE MAIN BODY PARTS

MAINTENANCE STANDARD OF CYLINDER HEAD
Unit: mm
Lengthwise direction Maximum 0.203 Repair by
Strain of cylinder head
1 grinding or
mounting face Lateral direction Maximum 0.075 replace
60-10 114E-6 SERIES

60 MAINTENANCE STANDARD ENGINE MAIN BODY PARTS
Unit: mm
Procedure Target
Tightening torque of 1st stage 50 Nm {5.1 kgm}

cylinder head mounting 2nd stage 150 Nm {15.3 kgm}
bolt
3rd stage Loosen 360 °
(Apply engine oil to un- Tighten and
2 derside of cylinder 4th stage 115 Nm {11.7 kgm} retighten
head mounting bolt.) 5th stage 115 Nm {11.7 kgm} (*)
6th stage Retighten 120 °

Using limit of length of
cylinder head mounting Below 162.6
bolt stem
Protrusion of injector Replace noz-
3 2.43 to 3.18
nozzle zle or gasket
Tightening torque of in- Target
4 jector holder mounting
bolt 9.8 Nm {1.0 kgm}
Tighten
Tightening torque of
5 head cover mounting 12 Nm {1.2 kgm}
bolt:
*: Tighten in order of numbers in [ ] in the figure.
114E-6 SERIES 60-11

MAINTENANCE STANDARD OF CYLINDER BLOCK
Unit: mm
No
Item Criteria Remedy
.
Strain of cylinder head Lengthwise direction Max. 0.075 Repair by grinding or re-
1
mounting face Lateral direction Max. 0.075 place
2 Main bearing thickness 3.446 to 3.454 Replace main bearing

Inside diameter of cam-
Repair or replace cylinder
3 shaft bushing mounting Max. 64.013
block
hole
4 Inside diameter of cam- Replace camshaft bushing
Max. 60.120
shaft bushing
60-12 114E-6 SERIES

Unit: mm
No
Item Criteria Remedy
.
Tightening torque of Procedure Target
main bearing cap (Ap- Tighten and retighten
5 1st stage 60 Nm {6.1 kgm}
ply engine oil to thread (*)
portion) 2nd stage Retighten 120 °
Tightening torque of Target Tighten
6 engine oil pan mount-
ing bolt 28 Nm {2.8 kgm} (*)
Tightening torque of
7 crankshaft pulley 200 Nm {20.4 kgm} Tighten
mounting bolt
114E-6 SERIES 60-13

MAINTENANCE STANDARD OF CYLINDER LINER
Unit: mm
Inside diameter of cylinder
114.000 to 114.040
liner
Replace cylin-
1 Roundness of cylinder liner
Repair limit: 0.04 der liner
bore
Taper of cylinder liner bore Repair limit: 0.04
Replace cylin-
2 Protrusion of cylinder liner 0.026 to 0.122 der liner or cyl-
inder block
Outside diameter of cylin- Replace cylin-
3 130.938 to 130.958
der liner der liner
60-14 114E-6 SERIES

Unit: mm
Inside diameter of cylinder
4 block (cylinder liner mount- 130.900 to 130.950 Replace or re-
ing portion) pair cylinder
liner or cylinder
Clearance between cylin- block
5 Min. 0.229
der liner and cylinder block
114E-6 SERIES 60-15

MAINTENANCE STANDARD OF CRANKSHAFT
Unit: mm
Replace thrust
1 End play 0.109 to 0.306
bearing
Standard 98.019
Outside diameter of main 0.25 undersize 97.769

journal 0.50 undersize 97.519 ±0.013 Under size re-
0.75 undersize 97.269 pair or replace
2
1.00 undersize 97.019
Roundness Max. 0.0064
Taper Max. 0.013
Replace main
Clearance in main journal 0.051 to 0.111
bearing
60-16 114E-6 SERIES

Unit: mm
Standard 76.013
Outside diameter of crank- 0.25 undersize 75.763

pin journal 0.50 undersize 75.513 ±0.013 Under size re-
0.75 undersize 75.263 pair or replace
3
1.00 undersize 75.013
Roundness Max. 0.0064
Taper Max. 0.013
Replace con-
Clearance in crankpin jour-
0.024 to 0.100 necting rod
nal
bearing
114E-6 SERIES 60-17

MAINTENANCE STANDARD OF PISTON
Unit: mm
Top ring 0.30 to 0.40
Abutment joint clearance of Replace piston
1 Second ring 0.70 to 1.00
piston ring ring or piston
Oil ring 0.30 to 0.60
Outside diameter of piston
2 44.997 to 45.003 Replace piston
pin
or piston pin
3 Piston pin bore diameter 45.006 to 45.012
60-18 114E-6 SERIES

MAINTENANCE STANDARD OF CONROD
Unit: mm
Standard dimension Tolerance Repair limit Replace bush-
Inside diameter of connecting (Spare
ing rod small end bushing +0.041 bushing is half
48 48.08
1 +0.025 finished)
Clearance between con- Standard clearance Allowable clearance Replace bush-
necting rod small end ing or piston
bushing and piston pin 0.025 to 0.047 0.10 pin
Inside diameter of connect-
Replace con-
2 ing rod small end bushing +0.030
53 necting rod
mounting hole
0
114E-6 SERIES 60-19

Unit: mm
Inside diameter of connect- Standard dimension Tolerance Repair limit

3 ing rod big end metal +0.020 Replace metal
(Crankpin journal) 80 80.12
-0.010
+0.022
Inside diameter of connect- 85 -
-0.004 Replace con-
ing rod big end metal
necting rod
mounting hole
4 Tighten connecting rod cap to specified torque, then measure.
Connecting rod metal +0.005

2.5 - Replace metal
thickness -0.004
Item Standard Repair limit
Parallelism and distortion Parallelism a 0 to 0.20 0.25 Replace con-

5
of connecting rod Distortion b 0 to 0.30 0.35 necting rod
Dimension c 240 -
Tightening torque of con- Procedure Target Range
necting rod cap mounting
93 to 103 Nm {9.5
bolt 1st stage 98 Nm {10 kgm}
6 to 10.5 kgm} Retighten
(Apply engine oil to thread
portion of bolt and seat of Retighten
2nd step Retighten 90 °
nut) 90(+30/0) °
Allowable range: Dispersion of weight in 1 machine must be

- Weight of connecting rod Replacement
Max. 140 g
REMARK
• Limit the reuse of the connecting rod cap mounting bolt to 5 times.
• Make a punch mark on the bolt each time it is used.
60-20 114E-6 SERIES

MAINTENANCE STANDARD OF VIBRATION DAMPER
Unit: mm
1 Appearance check Must be free from breakage, inflation, and dent. Replace
Tightening torque of vibra- Target

2 Tighten
tion damper mounting bolt 200 Nm {20.4 kgm}
114E-6 SERIES 60-21

MAINTENANCE STANDARD OF TIMING GEAR
Unit: mm
Backlash of engine
A 0.08 to 0.33
oil pump gear
Backlash of cam-
1 Backlash of each gear B 0.08 to 0.33 Replace
shaft gear
Backlash of idler
C 0.08 to 0.33
gear
60-22 114E-6 SERIES

MAINTENANCE STANDARD OF CAMSHAFT
Unit: mm
Replace thrust
1 End play 0.10 to 0.36
plate
Outside diameter of cam- Repair or re-
2 59.962 to 60.013
shaft journal place
Thickness of camshaft
3 9.40 to 9.60 Replace
thrust plate
Tightening torque of cam- Target
4 shaft thrust plate mounting Tighten
bolt 24 Nm {2.4 kgm}
114E-6 SERIES 60-23

MAINTENANCE STANDARD OF VALVE AND VALVE GUIDE
Unit: mm
Valve sink into cylinder Replace valve
1 0.70 to 1.16
head (A) or valve seat
Intake Min. 2.06
2 Valve rim thickness (B) Replace valve
Exhaust Min. 1.65
Valve Angle Repair limit
Repair or re-
3 Valve seat angle Intake 30 ° Judge contact sur- place valve or
face state by vac- valve seat
Exhaust 45 ° uum test
60-24 114E-6 SERIES

Unit: mm
Outside diameter of valve
4 7.96 to 7.98
stem Replace valve
5 Valve guide bore diameter 8.019 to 8.039
Driven height of valve
6 13.15 to 13.65 Repair
guide
114E-6 SERIES 60-25

MAINTENANCE STANDARD OF ROCKER ARM
Unit: mm
Outside diameter of rocker Replace rocker
1 Min. 24.950
arm shaft arm shaft
Inside diameter of rocker Replace rocker
2 Max. 25.013
arm shaft hole arm
Replace rocker
Clearance between rocker
3 Max. 0.063 arm or rocker
arm shaft and rocker arm
arm shaft
Tightening torque of rocker Target
4 arm adjustment screw lock Tighten
nut 24 Nm {2.4 kgm}
Valve Repair limit

Valve clearance (when
5 Intake 0.30 Adjust
cooled)
Exhaust 0.56
Tightening torque of rocker Target

6 Tighten
arm mounting bolt 65 Nm {6.6 kgm}
60-26 114E-6 SERIES

MAINTENANCE STANDARD OF FLYWHEEL
Unit: mm
Facial runout of flywheel
1 Repair limit: 0.20
housing Reassemble and re-
Radial runout of flywheel pair
2 Repair limit: 0.20
housing
Tightening torque of fly- Target Tighten
3 wheel housing mounting
bolt 77 Nm {7.85 kgm} (*)
114E-6 SERIES 60-27

Unit: mm
Flywheel Allowable value
For clutch 0.013/φ25.4
4 Facial runout of flywheel Reassemble and re-
For torque convert- Diameter of measurement point x pair
er 0.0005
5 Radial runout of flywheel Repair limit: 0.13
Tightening torque of fly- Target
wheel mounting bolt (Apply Tighten and retighten
6
engine oil to threaded part 137 Nm {14.0 kgm} (*)
or seat surface)
60-28 114E-6 SERIES

60 MAINTENANCE STANDARD LUBRICATION SYSTEM
LUBRICATION SYSTEM
MAINTENANCE STANDARD OF ENGINE OIL PUMP
Unit: mm
Clearance in axial direction
1 0.025 to 0.127
of rotor
Clearance between outer Replace oil
2 0.178 to 0.381
rotor and body pump
Clearance between outer
3 0.025 to 0.178
rotor and inner rotor
Tightening torque of oil Target

4 Tighten
pump mounting bolt 24 Nm {2.4 kgm}
114E-6 SERIES 60-29

INDEX
INDEX
A CDR valve - Operation........................................10-76
Charge (boost) pressure and temperature sensor -
Abbreviation List.......... 00-4,01-3,10-4,20-3,50-3,60-3 Function..................................................... 10-125
Actions if fire occurs............................................00-22 Charge (boost) pressure and temperature sensor -
Actions taken to meet exhaust gas regulations.. 00-24 Structure.................................................... 10-125
AdBlue/DEF - Store............................................ 00-26 Coating materials list...........................................50-11
AdBlue/DEF hose............................................... 10-38 Common rail pressure sensor - Function..........10-129
AdBlue/DEF hose - Function.............................. 10-38 Common rail pressure sensor - Structure......... 10-129
AdBlue/DEF hose - Structure..............................10-38 Component parts of electrical system...............10-105
AdBlue/DEF injector............................................10-37 Component parts of urea SCR system............... 10-31
AdBlue/DEF injector - Function...........................10-37 Connecting rod - Maintenance standard.............60-19
AdBlue/DEF injector - Operation.........................10-37 Connector - Precautions for disconnection and con-
AdBlue/DEF injector - Structure..........................10-37 nection......................................................... 00-45
AdBlue/DEF mixing tube.....................................10-31 Connector with housing to rotate - Disconnect/
AdBlue/DEF mixing tube - Function....................10-31 Connect....................................................... 00-55
AdBlue/DEF mixing tube - Structure................... 10-31 Connector with lock to push - Disconnect/Connect......
AdBlue/DEF pump.............................................. 10-36 .....................................................................00-53
AdBlue/DEF pump - Structure............................ 10-36 Conversion table................................................. 00-70
AdBlue/DEF supply system - Function............... 10-14 Coolant temperature sensor - Function............ 10-126
AdBlue/DEF tank................................................ 10-34 Coolant temperature sensor - Structure............10-126
AdBlue/DEF tank - Structure...............................10-34 Cooling system................................................... 10-98
AdBlue/DEF tank heating valve.......................... 10-39 Cooling system - Circuit diagram........................ 10-99
AdBlue/DEF tank heating valve - Function......... 10-39 Cooling system parts - Layout drawing...............10-98
AdBlue/DEF tank heating valve - Operation....... 10-39 Crankcase pressure sensor - Function............. 10-135
AdBlue/DEF tank heating valve - Structure........ 10-39 Crankcase pressure sensor - Structure............ 10-135
AdBlue/DEF tank sensor.....................................10-35 Crankshaft - Maintenance standard....................60-16
AdBlue/DEF tank sensor - Function....................10-35 Cylinder block..................................................... 10-49
AdBlue/DEF tank sensor - Structure...................10-35 Cylinder block - Maintenance standard...............60-12
Air cleaner...........................................................10-45 Cylinder block - Specifications............................ 10-49
Air cleaner - Operation........................................10-45 Cylinder block - Structure....................................10-49
Air cleaner - Specifications................................. 10-45 Cylinder head......................................................10-47
Air cleaner - Structure......................................... 10-45 Cylinder head - Maintenance standard............... 60-10
Air cleaner clogging sensor - Function..............10-136 Cylinder head - Specifications............................ 10-47
Air cleaner clogging sensor - Structure.............10-136 Cylinder head - Structure.................................... 10-47
Alternator.......................................................... 10-105 Cylinder liner - Maintenance standard................ 60-14
Alternator with built-in regulator (open type, 140 A) -
Specifications.............................................10-107 D
Alternator with built-in regulator (open type, 140 A) -
Structure.................................................... 10-106 Deutsch connector - Disconnect/Connect...........00-49
Alternator with built-in regulator (open type, 90 A) - Drive pulley....................................................... 10-101
Specifications.............................................10-105 Drive pulley (Bulldozer) - Structure................... 10-101
Alternator with built-in regulator (open type, 90 A) - Drive pulley (Hydraulic excavator) - Structure.. 10-101
Structure.................................................... 10-105
Ambient pressure sensor - Function................. 10-123 E
Ambient pressure sensor - Structure................ 10-123
Applicable machines list:114E-6......................... 01-12 EGR cooler......................................................... 10-69
Assembly and disassembly - Related information 50-9 EGR cooler - Operation...................................... 10-69
EGR cooler - Structure........................................10-69
EGR system........................................................10-65
B EGR system - Circuit diagram............................ 10-66
Bkup (camshaft) speed sensor - Function........ 10-128 EGR system - Function.......................................10-65
Bkup (camshaft) speed sensor - Structure....... 10-128 EGR system - Layout drawing............................ 10-65
EGR system - Operation.....................................10-66
C EGR valve...........................................................10-67
EGR valve - Operation........................................10-68
CDR valve...........................................................10-76 EGR valve - Structure......................................... 10-67
1
INDEX
EGR valve lift sensor - Function....................... 10-130 Fuel main filter.................................................... 10-97
EGR valve lift sensor - Structure.......................10-130 Fuel main filter - Function................................... 10-97
Electrical system............................................... 10-105 Fuel main filter - Structure...................................10-97
Engine - General assembly.................................50-50 Fuel prefilter........................................................ 10-96
Engine - General disassembly............................ 50-19 Fuel prefilter - Function....................................... 10-96
Engine - General disassembly and assembly.....50-18 Fuel prefilter - Structure...................................... 10-96
Engine - Standard value table...............................20-9 Fuel system.........................................................10-89
Engine boost oil pump........................................ 10-84 Fuel system - Circuit diagram............................. 10-90
Engine boost oil pump - Function....................... 10-84 Fuel system - Function........................................10-90
Engine boost oil pump - Specifications............... 10-84 Fuel system equipment - Precautions for handling......
Engine boost oil pump - Structure.......................10-84 .....................................................................00-39
Engine components - Layout.............................. 10-40 Fuel system parts - Layout drawing.................... 10-89
Engine components - Layout drawing.................10-40
Engine controller............................................... 10-113 G
Engine controller - Function.............................. 10-113
Engine controller - Input and output signals......10-113 General character and precautions for handling.00-25
Engine controller - Structure............................. 10-113
Engine front oil seal - Install..............................50-109 H
Engine front oil seal - Remove..........................50-108
Engine front oil seal - Remove/Install............... 50-108 How to read electrical wire code......................... 00-56
Engine general view............................................01-16 How to read this manual....................................... 50-9
Engine main body parts............................ 10-47,60-10
Engine oil cooler................................................. 10-86 I
Engine oil cooler - Specifications........................ 10-86
Improved points of engine conformed to Tier 4 regula-
Engine oil cooler - Structure................................10-86
tion............................................................... 01-11
Engine oil filter.................................................... 10-85
Inducement strategy........................................... 10-17
Engine oil filter - Function................................... 10-85
Inducement strategy for abnormality recurrence with-
Engine oil filter - Specifications........................... 10-85
in 40 hours (For European Union)............... 10-30
Engine oil filter - Structure...................................10-85
Inducement strategy for abnormality recurrence with-
Engine oil pan..................................................... 10-88
in 40 hours (For North America).................. 10-23
Engine oil pan - Structure................................... 10-88
Inducement strategy when abnormality is found in the
Engine oil pressure switch - Function............... 10-124
AdBlue/DEF quality or in the Urea SCR system
Engine oil pressure switch - Structure.............. 10-124
devices (For European Union).....................10-24
Engine oil pump.................................................. 10-83
Engine oil pump - Function................................. 10-83
EGR system by the Urea SCR system devices
Engine oil pump - Maintenance standard........... 60-29
(For European Union).................................. 10-28
Engine oil pump - Specifications.........................10-83
Engine oil pump - Structure................................ 10-83
KDPF system by the Urea SCR system (For
Engine performance curve..................................01-28
North America).............................................10-20
Engine rear oil seal - Install...............................50-113
Engine rear oil seal - Remove...........................50-112
KDPF system by the urea SCR system devices
Engine rear oil seal - Remove/Install................ 50-112
(For European Union).................................. 10-26
Engine sensors - Layout drawing......................10-120
Engine shop manual - How to read.....................00-10
urea SCR system devices (For North America)....
Engine system.................................. 10-40,50-18,60-9
.....................................................................10-18
Engine wiring harness....................................... 10-111
Inducement strategy when the AdBlue/DEF level in
Engine wiring harness - Structure..................... 10-111
the tank becomes low (For European Union).......
Exhaust gas regulation - Outline...........................01-9
.....................................................................10-23
Inducement strategy when the AdBlue/DEF level in
F the tank becomes low (For North America). 10-17
Flywheel - Maintenance standard....................... 60-27 Intake air heater.................................................. 10-46
Flywheel / Flywheel housing - Specifications......10-58 Intake air heater - Specifications.........................10-46
Flywheel and flywheel housing........................... 10-58 Intake air heater - Structure................................ 10-46
Flywheel and flywheel housing - Structure......... 10-58 Intake and exhaust system - Function................ 10-43
Foreword, Safety, Basic information................... 00-10 Intake and exhaust systems - Circuit diagram.... 10-43
Front cover..........................................................10-56 Intake and exhaust systems - Layout drawing....10-42
Front cover - Structure........................................ 10-56 Intake and exhaust systems parts.............. 10-42,60-9
2
INDEX
Intake system equipment - Precautions for handling... Precautions for handling hydraulic equipment.... 00-27
.....................................................................00-40 Precautions for storing........................................ 00-25
Precautions to prevent fire.................................. 00-20
K Push-pull type coupler - Disconnect/Connect..... 00-41
KCCV system......................................................10-71
KCCV system - Forming of condensed water and
R
emulsion...................................................... 10-72 Rocker arm - Maintenance standard...................60-26
KCCV system - Function.....................................10-71 Running-in standard and performance test standard...
KCCV system - Layout drawing.......................... 10-71 .....................................................................20-21
KCCV system - Operation...................................10-74
KCCV ventilator.................................................. 10-75 S
KCCV ventilator - Function................................. 10-75
KCCV ventilator - Operation............................... 10-76 SAA6D114E-6 (D65EX-18, D65EX-18E0, D65EXI-18,
KCCV ventilator - Structure.................................10-75 D65EXI-18E0, D65PX-18, D65PX-18E0,
KDPF.................................................................. 10-77 D65PXI-18, D65PXI-18E0, D65WX-18,
KDPF - Function................................................. 10-78 D65WX-18E0) - Engine general view.......... 01-16
KDPF - Structure.................................................10-77 SAA6D114E-6 (D65EX-18, D65EX-18E0, D65EXI-18,
KDPF differential pressure and outlet pressure sen- D65EXI-18E0, D65PX-18, D65PX-18E0,
sor - Function.............................................10-134 D65PXI-18, D65PXI-18E0, D65WX-18,
KDPF differential pressure and outlet pressure sen- D65WX-18E0) - Engine performance curve 01-28
sor - Structure............................................ 10-134 SAA6D114E-6 (D65EX-18, D65EX-18E0, D65EXI-18,
D65EXI-18E0, D65PX-18, D65PX-18E0,
D65PXI-18, D65PXI-18E0, D65WX-18,
L D65WX-18E0) - Specifications.................... 01-13
Lubrication system....................................10-81,60-29 SAA6D114E-6 (D65EX-18, D65EX-18E0, D65EXI-18,
Lubrication system - Circuit diagram...................10-82 D65EXI-18E0, D65PX-18, D65PX-18E0,
Lubrication system parts - Layout drawing......... 10-81 D65PXI-18, D65PXI-18E0, D65WX-18,
D65WX-18E0) - Standard value table for engine..
M .......................................................................20-9
SAA6D114E-6 (D65EX-18, D65EXI-18, D65PX-18,
Main drive parts - Specifications......................... 10-52 D65PXI-18, D65WX-18) - Running-in standard
Main drive parts - Structure.................................10-51 and performance test standard....................20-21
Main moving parts...............................................10-51 SAA6D114E-6 (D65EX-18E0, D65EXI-18E0,
Maintenance standard of camshaft.....................60-23 D65PX-18E0, D65PXI-18E0, D65WX-18E0) -
Mass air flow and temperature sensor - Function........ Running-in standard and performance test stand-
...................................................................10-133 ard................................................................20-23
Mass air flow and temperature sensor - Structure....... SAA6D114E-6 (HB365LC-3, PC360LC-11,
...................................................................10-133 PC360LCI-11) - Engine performance curve.01-29
Method for disconnecting and connecting connector SAA6D114E-6 (HB365LC-3) - Engine general view....
with lock to pull............................................ 00-52 .....................................................................01-20
SAA6D114E-6 (HB365LC-3) - Running-in standard
N and performance test standard....................20-25
SAA6D114E-6 (HB365LC-3) - Specifications..... 01-14
NE (crankshaft) speed sensor - Function......... 10-127 SAA6D114E-6 (HB365LC-3) - Standard value table
NE (crankshaft) speed sensor - Structure ........10-127 for engine.....................................................20-13
SAA6D114E-6 (PC360LC-11, PC360LCI-11) - Engine
P general view.................................................01-24
SAA6D114E-6 (PC360LC-11, PC360LCI-11) - Run-
Piping - Precautions for disconnection and connec-
ning-in standard and performance test standard..
tion............................................................... 00-30
.....................................................................20-26
Piston - Maintenance standard........................... 60-18
SAA6D114E-6 (PC360LC-11, PC360LCI-11) - Speci-
Piston ring........................................................... 10-53
fications........................................................01-15
Piston ring - Structure......................................... 10-53
SAA6D114E-6 (PC360LC-11, PC360LCI-11) - Stand-
Precautions for adding........................................ 00-25
ard value table for engine............................ 20-17
Precautions for DEF............................................00-25
Safety notice for operation.................................. 00-12
Precautions for disposing of waste materials......00-23
Safety valve of engine oil filter............................ 10-87
Precautions for fire hazard and leakage............. 00-25
Safety valve of engine oil filter - Structure.......... 10-87
Precautions for handling electrical equipment.... 00-37
3
INDEX
Safety valve of engine oil filter-Specifications.....10-87 V

SCR assembly.................................................... 10-32
SCR assembly - Structure.................................. 10-32 Valve and valve guide - Maintenance standard.. 60-24
Sensor...............................................................10-120 Valve system.......................................................10-57
Slide lock type connector - Disconnect/Connect.00-50 Valve system - Structure..................................... 10-57
Special tools - List...............................................50-15 VGT.....................................................................10-61
Special tools - Sketches......................................50-17 VGT - Function....................................................10-62
Specification............................................... 01-9,01-13 VGT - Maintenance standard................................60-9
Standard tightening torque table.........................00-63 VGT - Operation..................................................10-63
Starting motor................................................... 10-108 VGT - Structure...................................................10-61
Starting motor (11 kw) with built-in safety relay - VGT position sensor - Function........................ 10-132
Structure.................................................... 10-109 VGT position sensor - Structure........................10-132
Starting motor (7.5 kw) with built-in safety relay - VGT speed sensor - Function........................... 10-131
Structure.................................................... 10-108 VGT speed sensor - Structure.......................... 10-131
Starting motor with built-in safety relay (11 kW) - VGT system - Circuit diagram.............................10-59
Specifications.............................................10-109 VGT system - Function....................................... 10-60
Starting motor with built-in safety relay (7.5 kW) - Vibration damper.................................................10-54
Specifications.............................................10-108 Vibration damper - Function................................10-54
Supply pump....................................................... 10-93 Vibration damper - Maintenance standard..........60-21
Supply pump - Function...................................... 10-94 Vibration damper - Structure...............................10-54
Supply pump - Operation.................................... 10-94
Supply pump - Structure..................................... 10-93 W
Supply pump assembly - Install........................ 50-104
Supply pump assembly - Remove.................... 50-102 Water pump.......................................................10-103
Supply pump assembly - Remove/Install..........50-102 Water pump - Structure.....................................10-103
Water-in-fuel sensor - Function.........................10-137
Water-in-fuel sensor - Structure........................ 10-137
T
Temporary restoration from Inducement (For Europe-
an Union) - Function.................................... 10-29
Temporary restoration from Inducement (For North
America) - Function..................................... 10-23
Terms for maintenance standard - Explanation.. 00-60
The other precautions......................................... 00-25
Thermostat........................................................10-104
Thermostat - Specifications.............................. 10-104
Thermostat - Structure...................................... 10-104
Tier 4 engine - System diagram.......................... 01-10
Timing gear......................................................... 10-55
Timing gear - Maintenance standard.................. 60-22
Timing gear - Structure....................................... 10-55
Turbocharger system.......................................... 10-59
Type 1 push-pull type coupler - Disconnect/Connect...
.....................................................................00-41
.....................................................................00-42
.....................................................................00-43
Types of regeneration - Function........................ 10-79
U
Urea SCR system............................................... 10-10
Urea SCR system - Function.............................. 10-14
Urea SCR system - Layout drawing....................10-10
Urea SCR system - System diagram.................. 10-12
4
114E-6 SERIES ENGINE
Form No. SEN06506-08
©2019 KOMATSU
All Rights Reserved
Printed in Japan 01-2019

Sen06506-08 114e-6 Series Engines

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Sen06506-08 114e-6 Series Engines

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SEN06506-08

ENGINE 114E -6 SERIES

114E-6 SERIES 00-1

00-2 114E-6 SERIES

20 STANDARD VALUE TABLE ...................................................................................................................... 20-1

114E-6 SERIES 00-3

00-4 114E-6 SERIES

Purpose of use (major ap-

114E-6 SERIES 00-5

Purpose of use (major ap-

Komatsu Catalyzed This is a filter that captures soot in exhaust gas.

00-6 114E-6 SERIES

Purpose of use (major ap-

114E-6 SERIES 00-7

Purpose of use (major ap-

*1: Code for applicable machine model

00-8 114E-6 SERIES

Abbreviation Actual word spelled out

114E-6 SERIES 00-9

FOREWORD, SAFETY, BASIC INFORMATION

00-10 114E-6 SERIES

Symbol Item Remark

114E-6 SERIES 00-11

SAFETY NOTICE FOR OPERATION

00-12 114E-6 SERIES

• Always wear the protective eyeglasses when hitting parts

Precautions during work

114E-6 SERIES 00-13

• Before starting work, shut down the engine. When working

00-14 114E-6 SERIES

Precautions for slinging work and making signals

114E-6 SERIES 00-15

00-16 114E-6 SERIES

114E-6 SERIES 00-17

Precautions for disconnecting air conditioner piping

00-18 114E-6 SERIES

114E-6 SERIES 00-19

PRECAUTIONS TO PREVENT FIRE

00-20 114E-6 SERIES

114E-6 SERIES 00-21

ACTIONS IF FIRE OCCURS

00-22 114E-6 SERIES

PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS

114E-6 SERIES 00-23

ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS

00-24 114E-6 SERIES

PRECAUTIONS FOR DEF

PRECAUTIONS FOR ADDING

PRECAUTIONS FOR STORING

PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE

THE OTHER PRECAUTIONS

114E-6 SERIES 00-25

*: Do not store AdBlue/DEF in the temperature of 35 °C or above.

00-26 114E-6 SERIES

PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT

• In the field, there is a risk of dust entering the component

Sealing of openings (prevention of flowing out of oil)

114E-6 SERIES 00-27

Preventing intrusion of foreign materials during refilling

Replacing hydraulic oil while its temperature is high

00-28 114E-6 SERIES

114E-6 SERIES 00-29

PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS