Komatsu S6D95L-1KK-1(S/N 35360-UP)
Maintenance schedule, common problems & OEM parts breakdown
The Komatsu S6D95L-1KK-1 engine is a 4-cycle, water-cooled, direct injection diesel powerplant used in the Komatsu 95 Series family, specifically powering the FD60H, FD70H, and FD80H-5 forklift models. It delivers 110 HP at 2,000 rpm with a maximum torque of 41.5 kgm at 1,500 rpm. This inline-six configuration replaced earlier 6D95L variants and serves as a robust workhorse for industrial and construction applications. The engine is characterized by its durability and is often found in mid-size excavators and forklifts from the late 1990s and early 2000s.
Across the 95 Series generations, the S6D95L-1KK-1 represents a stabilized design phase following the initial 6D95L introduction. It is common in the used and parts market as it is a failure point for aging PC200 and FD-series equipment, driving demand for reliable rebuild kits and cylinder heads. The engine's widespread use in the PC200-5 and PC200-6 excavator lines ensures a steady supply of used cores and aftermarket components, making it critical for fleet maintenance and overhaul planning.
Below: full specifications, fluids & capacities, the factory service schedule, common service parts, verified fault codes, what owners discuss, attachment guidance, the complete assembly directory, and a serial-number reference. Complete parts lists with full OEM part numbers, exploded diagrams, quantities, and fitment data are available free in Heavy Parts AI.
Komatsu S6D95L-1KK-1(S/N 35360-UP) specifications
Engine
| Model | S6D95L-1KK-1 |
| Configuration | 6-cylinder in-line, turbocharged, aftercooled |
| Displacement | 4.890 L (298.4 cu in) |
| Bore x Stroke | 95 mm x 115 mm (3.74 in x 4.53 in) |
| Gross Power | 110 HP (82 kW) @ 2,000 rpm |
| Maximum Torque | 41.5 kgm (300 ft·lbf) @ 1,500 rpm |
| Emissions Tier | Not documented for this exact serial range — verify with your dealer |
Weights
| Operating Weight | Not documented for this exact serial range — verify with your dealer |
| Shipping Weight | Not documented for this exact serial range — verify with your dealer |
| Engine Dry Weight | 425 kg (937 lb) |
Dimensions
| Overall Length | 986 mm (38.8 in) |
| Overall Width | 586 mm (23.1 in) |
| Overall Height | 876 mm (34.5 in) |
Performance
| High Idling Speed | 2,500 ± 50 rpm |
| Low Idling Speed | 700 ± 25 rpm |
| Minimum Fuel Consumption | 160 g/HPh |
| Travel Speeds | Not documented for this exact serial range — verify with your dealer |
| Gradeability | Not documented for this exact serial range — verify with your dealer |
Service capacities (summary)
| Fuel Tank | Not documented for this exact serial range — verify with your dealer |
| Hydraulic System | Not documented for this exact serial range — verify with your dealer |
| Engine Oil | 12.5 L (3.3 gal) |
| Cooling System | 18 L (4.8 gal) |
Values vary by configuration, region, and serial range — confirm against your machine before planning transport or lifts.
S6D95L-1KK-1(S/N 35360-UP) fluids & capacities
| System | Capacity | Recommended fluid |
|---|---|---|
| Engine crankcase (with filter) | 11 L (2.9 US gal) | Komatsu EO or equivalent diesel engine oil; viscosity varies by climate per factory spec sheet |
| Cooling system | 7.5 L (2.0 US gal) to 8.5 L (2.2 US gal) | Komatsu Super Coolant AF-NAC or equivalent ethylene glycol coolant |
| Fuel tank | not documented for this exact serial range — verify with your dealer | not documented for this exact serial range — verify with your dealer |
| Transmission/powertrain compartments | not documented for this exact serial range — verify with your dealer | not documented for this exact serial range — verify with your dealer |
| Final drives (each) | not documented for this exact serial range — verify with your dealer | not documented for this exact serial range — verify with your dealer |
| Hydraulic system AND tank | not documented for this exact serial range — verify with your dealer | not documented for this exact serial range — verify with your dealer |
| Axles/differentials | not documented for this exact serial range — verify with your dealer | not documented for this exact serial range — verify with your dealer |
| Grease | not applicable | not documented for this exact serial range — verify with your dealer |
Capacities are refill values from factory literature — always fill to the dipstick/sight gauge, not the number.
Komatsu S6D95L-1KK-1(S/N 35360-UP) maintenance schedule
| Service interval | Tasks |
|---|---|
| Every 10 h |
|
| Every 250 h |
|
| Every 500 h |
|
| Every 1,000 h |
|
| Every 2,000 h |
|
Servicing the S6D95L-1KK-1(S/N 35360-UP) beyond the schedule
Predictive Maintenance & Fluid Analysis
Utilize KOWA fluid analysis at every 500-hour interval to monitor engine oil wear metals (iron, copper, lead, aluminum) and contaminants like silicon and sodium. Check hydraulic fluid particle count and viscosity. Test coolant pH, SCA concentration, and glycol content. Monitor DEF levels daily on Tier 4 variants. Track KOMTRAX telematics for load frequency and fault codes to anticipate failures before they occur.
Corrective & Common Repairs
Address valve clearance drift and improper torque on main/rod bearings to prevent bearing failure or head gasket leaks. Inspect the turbocharger T04B59 for wear. Check the oil pump 6209-51-1400 for consistent lubrication pressure. Replace the cylinder head 6209-11-1100 if cracked or warped. Ensure the starter motor 600-the OEM part reference engages correctly. Fix hydraulic hose leaks and check pins/bushings for wear.
Overhaul & Rebuild Points
Perform in-frame overhaul at 10,000 hours or when compression drops. Replace pistons, rings, and cylinder liners. Inspect the crankshaft assembly and camshaft for wear. Replace the timing gear case and flywheel housing if damaged. Use out-of-frame overhaul kits for severe cases. Verify torque specs on head bolts and rocker shafts during reassembly to ensure proper sealing and performance.
Seasonal & Environment Servicing
In cold weather, check coolant freeze protection and use appropriate viscosity engine oil. In hot environments, clean radiator and oil cooler fins daily to prevent overheating. Inspect air filter elements more frequently in dusty conditions. Check track tension and undercarriage wear on excavators operating in abrasive terrain. Ensure DEF system components are protected from freezing and contamination.
S6D95L-1KK-1(S/N 35360-UP) common service parts
| Part number | Part | Notes | |
|---|---|---|---|
| 07281-00197 | Clamp,(With Pre-Fuel Filter) | Fuel system service | Check fitment → |
| 600-311-1320 | Plate? Caution,Fuel Filter | Fuel system service | Check fitment → |
| 600-311-8221 | Cartridge,Engine Fuel Filter | Fuel system service | Check fitment → |
| 6136-71-6120 | Cartridge,Engine Fuel Filter | Fuel system service | Check fitment → |
| 6204-71-6100 | Fuel Filter Ass'Y | Fuel system service | Check fitment → |
Always confirm against your machine's serial number — cross-check any part in Heavy Parts AI before ordering.
S6D95L-1KK-1(S/N 35360-UP) fault codes & troubleshooting
| Code | Meaning | Likely cause | What to do |
|---|---|---|---|
| CA115 | Engine crankshaft speed sensor and backup speed sensor failure | Faulty speed sensor, broken wiring harness, or corroded connector at the sensor pin | Inspect the sensor wiring and connector; replace the speed sensor if voltage is abnormal at the pin |
| CA451 | Common rail pressure sensor feedback value too high | Malfunctioning rail pressure sensor or actual overpressure condition in the fuel line | Diagnose the fuel rail pressure sensor and check pump lines for blockage or restriction |
| CA122 | Intake air pressure sensor feedback voltage too high | Faulty intake pressure sensor or shorted wiring | Verify the intake pressure sensor operation and inspect the wiring harness for damage |
| AA10NX | Air cleaner clogging | Clogged air filter element due to dust or debris | Replace the air filter element |
| CA441 | Battery voltage too low | Weak battery, failing alternator, or loose connections | Check battery health and replace the alternator or battery if voltage regulation is faulty |
| B@BCNS | Engine coolant overheating | Low coolant level, blocked radiator fins, or failed fan belt | Check radiator fins, fan belt tension, and coolant level; fill coolant and inspect for leaks |
| CA111 | Internal engine controller fault | Critical internal failure of the Electronic Control Module (ECM) | Replace or reprogram the ECM |
| CA234 | Engine overspeed | Incorrect throttle calibration, excessive engine load cycle, or operator misuse | Verify throttle calibration and review engine load cycles and operator inputs |
| CA153 | Intake air temperature sensor feedback voltage too high | Faulty intake air temperature (IAT) sensor | Replace or test the IAT sensor |
| AB00KE | Charging voltage too low | Failing alternator or loose drive belt | Replace the alternator or tighten the belt |
Codes and remedies are general guidance for this model family — always confirm with diagnostic tooling and your dealer before major repairs.
S6D95L-1KK-1(S/N 35360-UP) attachments & work tools
Excavator Buckets
The S6D95L-1KK-1 engine powers the PC200-5, PC210LC-6L, PC220LC-5, and PC250LC-6L excavator series. Standard bucket capacities for this class range from 0.8 to 1.2 cubic meters (0.99 to 1.48 cubic yards), varying by configuration and series.
Hydraulic Coupler Systems
Factory configurations for the PC200-5 and PC220LC-5 series utilize standard quick-attach couplers compatible with the machine's hydraulic flow. Specific coupler models vary by configuration and series.
Hydraulic Kit Requirements
Work tools such as breakers or hammers require specific hydraulic flow and pressure settings matched to the engine's output. The S6D95L-1KK-1 (S/N 35360-UP) provides the powertrain for these attachments, but tool-specific hydraulic kits are not documented for this exact serial range in the provided sources.
Factory Guarding Options
The PC200-5Z and PC200-6L series equipped with this engine typically include factory-installed guarding for the undercarriage and hydraulic lines. Specific guarding configurations vary by configuration and series.
All S6D95L-1KK-1(S/N 35360-UP) assemblies by section
Every catalogued assembly group for the Komatsu S6D95L-1KK-1(S/N 35360-UP). Open an assembly to preview the parts inside — full OEM part numbers are available in Heavy Parts AI.
Cooling System
Komatsu : S6d95l-1kk-1(S/N 35360-Up) : Cooling System : Water Pump And Cooling Fan
| 01***35 | Bolt,(For Quick Shift) (Mitsubishi) | 6 |
| 01***16 | Screw | 5 |
| 01***20 | Screw | 2 |
Cylinder Block
Komatsu : S6d95l-1kk-1(S/N 35360-Up) : Cylinder Block : Camshaft And Tappet
| 01***20 | Screw | 2 |
| 04***16 | Fitting Wedge | 1 |
| 62***10 | Tappet | 12 |
Komatsu : S6d95l-1kk-1(S/N 35360-Up) : Cylinder Block : Crankshaft
| 01***45 | Bolt,Nylock | 1 |
| 01***16 | Bolt,(With Alternator Cover Type) | 6 |
| 01***20 | Bolt,(For Japan Pc200) | 6 |
Komatsu : S6d95l-1kk-1(S/N 35360-Up) : Cylinder Block : Cylinder Block
| 01***16 | Screw | 1 |
| 01***06 | Nut | 1 |
| 01***10 | Washer,See Fig. K4010-12a0 | 1 |
Komatsu : S6d95l-1kk-1(S/N 35360-Up) : Cylinder Block : Flywheel And Flywheel Housing(#84734-)
| 01***30 | Bolt | 6 |
| 01***30 | Bolt - Lower Oil Cooler Outlet Tubemounting | 11 |
| 01***14 | Bolt,(With Corrosion Resistor) | 1 |
Komatsu : S6d95l-1kk-1(S/N 35360-Up) : Cylinder Block : Front Cover And Gear
| 01***70 | Bolt,(For 75a Alternator) | 1 |
| 01***16 | Bolt | 2 |
| 01***16 | Screw | 2 |
Komatsu : S6d95l-1kk-1(S/N 35360-Up) : Cylinder Block : Oil Pan
| 01***10 | Bolt, Mount Flasher | 3 |
| 01***12 | Bolt,(Without R.P.C.U.) | 3 |
| 01***16 | Bolt, Mount Solenoid Valve | 28 |
Komatsu : S6d95l-1kk-1(S/N 35360-Up) : Cylinder Block : Piston And Connecting Rod
| 04***12 | Ring, Snap | 12 |
| 62***10 | Bolt | 2 |
| 62***41 | Piston (S) | 6 |
Cylinder Head
Komatsu : S6d95l-1kk-1(S/N 35360-Up) : Cylinder Head : Air Cleaner And Connection (Double Element Type)(#82576-)
| 01***20 | Screw | 2 |
| 01***05 | Screw | 2 |
| 01***07 | Nut,Lock | 2 |
Komatsu : S6d95l-1kk-1(S/N 35360-Up) : Cylinder Head : Air Intake Manifold And Connection
| 01***12 | Bolt | 2 |
| 01***25 | Bolt,(With Corrosion Resistor) | 11 |
| 01***70 | Bolt | 2 |
Komatsu : S6d95l-1kk-1(S/N 35360-Up) : Cylinder Head : Cylinder Head
| 01***20 | Bolt, Hose Clamps (Inlet And Return Line Hoses) | 4 |
| 01***32 | Washer,(Not Used With Emergency Str.) | 25 |
| 01***32 | Washer, (Without Emergency Steering) | 25 |
Komatsu : S6d95l-1kk-1(S/N 35360-Up) : Cylinder Head : Cylinder Head Cover
| 01***16 | Bolt,(With Alternator Cover Type) | 1 |
| 04***50 | Screw | 4 |
| 07***80 | Clamp, Drain Hose | 1 |
Komatsu : S6d95l-1kk-1(S/N 35360-Up) : Cylinder Head : Exhaust Manifold And Turbocharger
| 01***16 | Bolt,(Sandy And Dusty Spec.) | 1 |
| 01***25 | Grub Screw | 4 |
| 01***80 | Bolt (M10-1.50x80) | 11 |
Komatsu : S6d95l-1kk-1(S/N 35360-Up) : Cylinder Head : Muffler And Mounting
| 01***60 | Bolt (M10-1.50x60) | 2 |
| 01***40 | Bolt | 4 |
| 01***20 | Bolt, Hose Clamps (Inlet And Return Line Hoses) | 1 |
Komatsu : S6d95l-1kk-1(S/N 35360-Up) : Cylinder Head : Rocker Arm
| 01***65 | Bolt,(For Alternator Bracket Mount) | 8 |
| 61***30 | Circlip | 2 |
| 62***20 | Spring | 5 |
Komatsu : S6d95l-1kk-1(S/N 35360-Up) : Cylinder Head : Turbocharger
| 62***10 | Turbocharger Ass'Y | 1 |
| GA***00 | Clamp | 3 |
| GA***01 | Bolt | 6 |
Electrical System
Komatsu : S6d95l-1kk-1(S/N 35360-Up) : Electrical System : Alternator (25a)
| 60***30 | Alternator A. (25a),(With Non Hardening Pulley) | 1 |
| KD***57 | Bearing,Ball? Front | 1 |
| KD***11 | Rear Bracket Ass'Y | 1 |
Komatsu : S6d95l-1kk-1(S/N 35360-Up) : Electrical System : Alternator And Mounting (25a)
| 01***40 | Bolt,(Cold Weather Spec.) | 1 |
| 01***25 | Bolt,(With Corrosion Resistor) | 3 |
| 01***65 | Bolt,(For 35a? 25a Alternator) | 1 |
Komatsu : S6d95l-1kk-1(S/N 35360-Up) : Electrical System : Electrical Wiring
| 01***12 | Bolt,(See Fig.0501) | 2 |
| 01***14 | Bolt,(With Corrosion Resistor) | 6 |
| 01***16 | Bolt,(With Alternator Cover Type) | 1 |
Komatsu : S6d95l-1kk-1(S/N 35360-Up) : Electrical System : Starting Motor (5.5kw)
| 60***20 | Starting Motor Ass'Y,(5.5kw) | 1 |
| KD***30 | Bracket,Center | 1 |
| KD***40 | Washer Ass'Y,(Not Shown) | 1 |
Komatsu : S6d95l-1kk-1(S/N 35360-Up) : Electrical System : Starting Motor And Mounting (5.5kw)
| 01***16 | Bolt,(With Alternator Cover Type) | 1 |
| 01***30 | Bolt | 2 |
| 07***05 | O-Ring,(Not Used With Emergency Str.) (K2) | 1 |
Engine Kit
Komatsu : S6d95l-1kk-1(S/N 35360-Up) : Engine Kit : Gasket Kit
| 07***05 | O-Ring,(Not Used With Emergency Str.) (K2) | 1 |
| 07***35 | O-Ring,Hydraulic Oil Filter | 1 |
| 07***40 | O-Ring,Water Pump Mount | 2 |
Fuel System
Komatsu : S6d95l-1kk-1(S/N 35360-Up) : Fuel System : Fuel Filter And Piping
| 01***20 | Bolt,(For Japan Pc200) | 1 |
| 01***30 | Screw | 2 |
| 01***70 | Bolt | 1 |
Komatsu : S6d95l-1kk-1(S/N 35360-Up) : Fuel System : Fuel Injection Pump (Feed Pump)(#60958-)
| DK***20 | Bolt, Joint | 1 |
| DK***00 | Valve,Check | 2 |
| DK***10 | Feed Pump Ass'Y,(Not Shown) | 1 |
Komatsu : S6d95l-1kk-1(S/N 35360-Up) : Fuel System : Fuel Injection Pump (Governor) (1/2)(#60958-)
| DK***00 | Shim? 2.00mm,(High Altitude Spec.) | 0 |
| DK***00 | Adapter | 1 |
| DK***20 | Limiter | 1 |
Komatsu : S6d95l-1kk-1(S/N 35360-Up) : Fuel System : Fuel Injection Pump (Governor) (2/2)(#60958-)
| DK***40 | Gasket,Air Compressor | 2 |
| DK***00 | Nut,Cap | 1 |
| DK***20 | Cover | 1 |
Komatsu : S6d95l-1kk-1(S/N 35360-Up) : Fuel System : Fuel Injection Pump (Pump) (1/2)(#60958-)
| 62***11 | Injection Pump Ass'Y | 1 |
| 62***62 | Injection Pump Ass'Y | 1 |
| DK***30 | Key,Woodruff | 1 |
Komatsu : S6d95l-1kk-1(S/N 35360-Up) : Fuel System : Fuel Injection Pump (Pump) (2/2)(#60958-)
| DK***40 | Shim? 0.50mm, Shim, 0.50mm; Was Dk029311-0040 | 0 |
| DK***90 | Shim? 0.25mm, Shim, 0.25mm; Was Dk029311-0590 | 0 |
| DK***00 | Sleeve,Control | 6 |
Komatsu : S6d95l-1kk-1(S/N 35360-Up) : Fuel System : Fuel Injection Pump And Piping
| 01***35 | Stud | 4 |
| 01***25 | Screw | 4 |
| 01***12 | Bolt,(See Fig.0501) | 1 |
Komatsu : S6d95l-1kk-1(S/N 35360-Up) : Fuel System : Fuel Nozzle And Spill Pipe
| 01***35 | Bolt, Mount Bracket To Floor | 6 |
| 07***80 | Clip | 3 |
| 07***00 | Clip | 13 |
Lubricating Oil System
Komatsu : S6d95l-1kk-1(S/N 35360-Up) : Lubricating Oil System : Lubricating Oil Cooler(#72460-)
| 01***40 | Screw | 18 |
| 01***06 | Nut | 4 |
| 07***12 | T/Plug, Plug,(For Power Tilt Mech Angle) | 1 |
Komatsu : S6d95l-1kk-1(S/N 35360-Up) : Lubricating Oil System : Lubricating Oil Filter(#83351-)
| 01***30 | Bolt,(Water Separator Spec.) | 4 |
| 01***20 | Bolt,(For Japan Pc200) | 2 |
| 01***25 | Bolt,(With Corrosion Resistor) | 2 |
Komatsu : S6d95l-1kk-1(S/N 35360-Up) : Lubricating Oil System : Lubricating Oil Pump And Suction Pipe
| 01***12 | Bolt,(See Fig.0501) | 1 |
| 01***16 | Screw | 4 |
| 01***30 | Bolt,(Water Separator Spec.) | 2 |
Komatsu : S6d95l-1kk-1(S/N 35360-Up) : Lubricating Oil System : Turbocharger Lubricating Oil Piping
| 01***35 | Bolt, Mount Bracket To Floor | 1 |
| 01***40 | Bolt,(Shim 3-Piece) | 1 |
| 01***16 | Screw | 5 |
S6D95L-1KK-1(S/N 35360-UP) serial number reference
The engine serial number plate is located on the left side of the engine block, typically near the injection pump or on the valve cover. The machine's Product Identification Number (PIN) or chassis serial plate is riveted to the right-hand side of the cab on the lower frame, just behind the front idler or beneath the operator's window. Cross-reference the engine serial with the machine serial to confirm the correct parts catalog, as the S6D95L-1KK-1 engine is specified for machines with serial numbers 35360 and above in certain PC200 series generations.
| Prefix | Identifies | Notes |
|---|---|---|
| S6D95L-1KK-1 | Engine Model | Identifies the specific engine configuration (S6D95L-1KK-1) used in the machine. The serial number range 35360-UP is explicitly tied to this engine model in factory parts catalogs and equipment guides. This engine is a 4-cycle, water-cooled, direct injection diesel, typically producing 110 HP at 2,000 rpm with a maximum torque of 41.5 kgm (300 lb-ft) at 1,500 rpm. It is commonly found in PC200-5Z and PC200-6 series excavators. Note: The 'KK' suffix indicates a specific revision or configuration variant within the S6D95L family; verify exact mechanical differences with your dealer as sources list multiple S6D95L variants (JJ, MM, LL, NN, PP, TT, U) with overlapping or sequential serial breaks. |
Frequently asked questions
What is the engine model?
The engine model is S6D95L-1KK-1, a 4-cycle, water-cooled, direct injection diesel engine.
What is the operating weight of the machine?
Operating weight varies by configuration/series. Specific weights for the FD60H/FD70H/FD80H-5 forklifts are not documented in the source text; verify with your dealer.
What replaced it?
The S6D95L-1KK-1 is part of the 95 Series lineage. Successors in the Komatsu lineup include the SAA6D107E-2 and other Tier 4 compliant engines, but specific replacement models for this exact serial range are not documented in the source text.
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