Diesel Engine Komatsu 114E-3 Series SAA6D114E-3 Shop Manual (P/N SEN00169-09)

-* Machine coverage: Applies to the Komatsu SAA6D114E-3 in PC300-7E0, PC300LC-7E0, PC350-7E0, PC350LC-7E0, PC300-8, PC300LC-8, PC350-8, and PC350LC-8 excavators; the WA430-6 wheel loader; D65EX-15E0, D65PX-15E0, D65WX-15E0, D65EX-16, D65PX-16, and D65WX-16 dozers; and GD655-3E0 and GD675-3E0 motor graders.

• Internal engine repair: Covers general teardown and reassembly, including the cylinder head and valve gear, liners, pistons and connecting rods, crankshaft, camshaft and timing gears, oil pump, flywheel housing, front and rear seals, plus dedicated supply-pump head service.
• Testing and adjustment: Includes boost, compression, blow-by, lubricating-oil, and fuel-pressure tests; valve-clearance adjustment; reduced-cylinder operation; no-injection cranking; pressure-limiter and injector-return checks; fuel-system bleeding; and leak testing.
• Electronic and fuel diagnosis: Provides E-mode fault-code procedures, S-mode symptom charts, normal-state electrical values, connector and pin references, and related circuits for the ECM, sensors, injectors, lift pump, inlet metering valve, and intake-air heater.
• System reference: Explains intake and exhaust flow, variable-geometry and wastegated turbocharger operation, lubrication and cooling circuits, and the electronically controlled high-pressure common-rail fuel system.
• Document and data coverage: A 376-page Komatsu factory PDF, master Form No. SEN00169-09, compiled with revisions current to January 2009 and containing application-specific specifications, maintenance standards, torque tables, service limits, run-in standards, and performance-test criteria.

Because the procedures assume a repair stand, lifting equipment, precision pressure gauges, electrical T-adapters, and INSITE monitoring, this manual is suited to professional diesel technicians and experienced engine rebuilders working in a properly equipped shop.

Machine-Specific Engine Configurations

Application tables do not treat every installation as identical. They separate engine dimensions, rated performance, oil refill capacities, alternator and starter options, and run-in test data by machine group. The PC300/350 and WA430-6 tables specify Holset HX40W turbochargers; D65 and GD applications specify HX40 units. The WA430-6 is also identified as the air-compressor-equipped configuration.

Workshop Procedures and Diagnostic Depth

The test chapters pair each operation with the required gauges or adapters and the applicable standard values. Common-rail work covers residual-pressure handling, supply and rail-pressure checks, pressure-limiter leakage, injector return-rate measurement, air bleeding, and final leakage testing.

Engine disassembly begins with the removed power unit mounted on a stand, not with machine-specific engine removal. It works from external components through the head, gear train, rotating assembly, liners, and block, followed by a separate assembly sequence through valve adjustment and final oil refill. The supply pump receives its own pump-head replacement, inspection, and assembly section.

Fault-Code Diagnosis and Technical Drawings

Fifty-nine E-mode routines link INSITE and Komatsu machine codes to controller actions, likely causes, normal-state readings, and related circuits. Coverage includes ECM power, Ne and backup speed sensing, the combined boost pressure/temperature sensor, rail pressure, the IMV, all six injector circuits, the lift pump, intake-air heater, KOMNET/CAN, derate conditions, and overheat. Sixteen S-mode charts address no-start, poor response, power loss, black or blue smoke, oil/coolant cross-contamination, overheating, abnormal noise, and excessive vibration.

Named technical drawings include the variable-geometry turbocharger schematic, common-rail fuel-system flow, lubrication-for-power-components diagram, cooling-system routing, common-rail-pressure-sensor circuit, and CAN-communication circuit.

Specifications, Tools, and Repair Cautions

Maintenance-standard tables cover the cylinder head and block, liners, crankshaft, pistons and rods, timing train, camshaft, valve gear, flywheel and housing, turbocharger, and oil pump, with inspection limits and stated remedies. General tightening tables cover metric fasteners, eye joints, and split-flange joints.

Tool listings identify the 790-501-2001 repair stand, 795-799-6700 injector puller, and 795-799-1390 supply-pump remover. Liner work is supported by the 795-799-2170 puller and 795-799-2110 driver, while dedicated pressure-test kits and ECM/sensor T-adapters are also specified.

The rebuild cautions are component-specific: forcing a liner that does not enter smoothly can cut its sealing O-ring, while mixing supply-pump plungers or reinstalling them in the wrong direction can damage the engine.

Scope and Safety

This is the 114E-3 engine volume, not the complete machine shop manual. It does not provide chassis-specific engine removal/installation or full excavator hydraulic, loader drivetrain, dozer undercarriage, or grader chassis repair coverage; certain S-mode checks may refer back to the applicable machine’s chassis volume. Because the covered work involves residual common-rail pressure, injector-drive high voltage, rotating test work, and heavy lifting, service should be performed by qualified personnel using proper isolation and rated lifting equipment.