KOMATSU S6D114E-1, SA6D114E-1, SAA6D114E-1 Series Engine Shop Manual & Toubleshooting and Repair Manual

Shop Manual CEBM000601 SGD114E=i SAID1 14E=l SAAGD114E=i SERIES ENGINE SERIAL NUMBERS 45241940 andw This material is proprietary to Komatsu America International Company and is not to be reproduced, used, or disclosed except in accordance with written authorization from Komatsu America International Company. It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or add improvements at any time without incurring any obligation to install such changes on products sold previously. Due to this continuous program of research and development, periodic revisions may be made to this publication. It is recommended that customers contact their distributor for information on the latest revision. May 1997 Copyright 1997 Komatsu America International Company

CONTENTS SHOP MANUAL ....................................... 01 TROUBLESHOOTING & REPAIR MANUAL .................... 02

PRODUCT PUBLICATIONS INFORMATION VARIOUS PRODUCT PARTS & SERVICE PUBLICATIONS ARE AVAILABLE TO ALL KOMATSU CONSTRUCTION EQUIPMENT OWNERS, INCLUDING OPERATION AND MAINTENANCE MANUALS, PARTS BOOKS AND SERVICE MANUALS. SPECIAL PUBLICATIONS SUCH AS SERVICE TOOL, AIR CONDITIONING, AND TURBOCHARGER SERVICE MANUALS ARE ALSO AVAIlABLE AS WELL AS SELECTED OPERATION & SERVICE MANUALS IN FOREIGN LANGUAGES. THE PUBLICATION LISTED BELOW ARE AVAILABLE FOR THE 6D114E-1 SERIES ENGINE. DESCRIPTION FORM NUMBER SHOP MANUAL SET: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CEBM000601 Troubleshooting & Repair Manual PARTS AND SERVICE PUBLICATIONS CAN ONLYBEACQUIRED BY AUTHORIZED KOMATSU DISTRIBUTORS, USING THE KOMATSU PARTS INVENTORY PROCESSING SYSTEM (PIPS). IF THE PIPS SYSTEM IS NOT AVAILABLE AT THE DISTRIBUTOR LOCATION, THEN THE FOLLOWING REQUISITION FOR TECHNICAL SERVICE PUBLICATIONS AND SERVICE FORMS CAN BE USED. FORM KDC91D IS SHOWN ON THE REVERSE SIDE OF THIS PAGE. PUBINFO.KOM 021596

REQUISITION FOR TECHNICAL SERVICE PUBLlCATlONS AND SERVICE FORMS COMPLETE FORM AND RETURN TO - Komatsu America International Company 440 North Fairway Drive Vernon Hills, IL 60061-8112 U.S.A. Am: Technical Publications Fax No. (847) 970-4186 Tel No. (847) 970-5887 COMPANY NAME SHIP TO - ATTN. TYPE or PRINT STREET ADDRESS ORDER DATE ONLY . . CITY, STATE, ZIP CODE COUNTRY PHONE NO. FAX NO. SHIPPING METHOD DISTR/BRANCH CODE IMPORTANT - TO ASSURE SHIPMENT OF THE CORRECT PUBLICATION(S), THE MODEL NUMBER AND MACHINE SERIAL NUMBER MUST BE SHOWN. QN. PUBLICATION FORM NUMBER PARTS ;FaFe; PUBLICATION DESCRIPTION MODEL NUMBER SERIAL NUMBER g M-Microfiche KDC91 D 022597 CURRENT PRICES WILL BE CHARGED

Shop Manual S6D114E-1 SAGDI 14E-1 SAAGDI 14E-1 Series Engine 6D114E-I Series Engine

Foreword This manual contains complete rebuild specifications and information for the 6D114E-1 Series engines. The repair procedures in this manual are based on the engine being installed on an approved engine stand. Some rebuild procedures require the use of special service tools. Make sure the correct tools are used as described in the procedures. When a specific brand name, number, or special tool is referenced in this manual, an equivalent product can be used in place of the recommended item. A series of specific service manuals (Shop, Specification, Alternative Repair, and so forth) are available and can be ordered through your distributor using the form in the front of this book. The specifications and rebuild information in this manual is based on the information in effect at the time of printing. Komatsu America International Company reserves the right to make any changes at any time without obligation. If differences are found between your engine and the information in this manual, contact your Komatsu Distributor. The latest technology and the highest quality components are used to manufacture Komatsu engines. When replacement parts are needed, we recommend using only genuine Komatsu exchange parts.

Engine - Exploded View by Groups GROUP GROUP b9 GROUP 16 02

Table of Contents Page Introduction ................................................................. 1 Engine Identification ........................................................... E Engine Disassembly and Assembly - Group 00 .......................................... 0 Cylinder Block - Group 01 ....................................................... 1 Cylinder Head - Group 02 ..................................... . . . . . . . . . . . . . . . . . 2 Rocker Levers - Group 03 ..................................... . . . . . . . . . . . . . . . . . 3 Cam Followers - Group 04 ....................................................... 4 Fuel System - Group 05 ......................................................... 5 Injectors and Fuel Lines - Group 06 ................................................. 6 Lubricating Oil System - Group 07 ...... Cooling System - Group 08 .......... Drive Units - Group 09 .............. Air Intake System - Group 10 ......... . . . .................. 7 . . . .................. 8 . . . .................. 9 . . . ................. 10 Exhaust System - Group 11 ..................................................... 11 Air Equipment - Group 12 ...................................................... 12 Electrical Equipment - Group 13 .................................................. 13 Engine Testing - Group 14 ...................................................... 14 Instruments and Controls - Group 15 ............................................... 15 Mounting Adaptations - Group 16 ................................................. 16 Specifications and Torque Values - Group 18 .......................................... 18 Index ..................................................................... X

Section i - Introduction Page i-l Section i - Introduction Section Contents Page Aboutthe Manual .......................................................... General Cleaning instructions .................................................. Solvent and Acid Cleaning Steam Cleaning . . . . . . . General Repair Instructions General Safety Instructions Generic Symbols . . . . . . . Glossary of Terms . . . . . . How To Use This Manual . Group Contents . . . . . . . Index . . . . . . . . . . . . . . Metric Information, . . . . . Table of Contents . . . . . Illustrations . . . . . . . . . . . .................................................... .................................................... .................................................... .................................................... .................................................... .................................................... .................................................... .................................................... .................................................... .................................................... .................................................... .................................................... i-2 i-8 i-8 i-8 i-7 i-6 i-4 i-9 i-3 i-3 i-3 i-3 i-3 i-5

Page i-2 Section i - Introduction About the Manual This 6D114E-1 Series Shop Manual is intended to aid mechanics in disassembly, inspecting parts for reuse, rebuilding and assembly of components of the 6D114E-1 Series engines. The manual is divided into sections. Section 00 outlines the disassembly and assembly of the engine while the other section detail specific components. The procedures in this manual were developed for a shop environment with engine disassembly and assembly being performed on a rollover stand. A Group System has been used to subdivide the instructions by major components and systems. Refer to the Table of Contents (page i-l) for the various groups. The information is presented in very basic terms to make sure the instructions are easily understood. Wrench sizes and shop tooling are identified in the procedure when needed. Each group contains the following in sequence: l An Alphabetical Table of Contents (Index). l Exploded view(s) of all the components -in the group. l General Information Section(s) containing the basic service, maintenance, and design information necessary to assist in the rebuild of the engine or a component. l Procedural instructions for the disassembly, inspection, repair, and assembly that can be required to rebuild an engine. Additional repairs that are not essential during every rebuild, but can be necessary, are included. These repairs depend on the length of time an engine has been in service and the condition of the parts.

KOMATSU S6D114E-1, SA6D114E-1, SAA6D114E-1 Series Engine Shop Manual & Toubleshooting and Repair Manual

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