Komatsu 114E-3 Series Shop Manual Download Page 1

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SEN00169-05

ENGINE

114E

-3

SERIES

Summary of Contents for 114E-3 Series

Page 1: ...SEN00169 05 ENGINE 114E 3 SERIES...

Page 2: ......

Page 3: ...114E 3 Series 1 SEN00171 05 Engine 1SHOP MANUAL 114E 3 Series 00 Index and foreword 1 Index Composition of shop manual 2 Table of contents 3...

Page 4: ...gly Section Title Form Number Shop Manual contents binder binder label and tabs SEN00169 05 00 Index and foreword SEN00170 05 Index SEN00171 05 q Foreword and general information SEN00172 03 01 Specif...

Page 5: ...cal data SEN00174 02 General 2 Specifications 3 General view 8 Dimensions table 12 Engine performance curves 13 10 Structure function and maintenance standard Structure function and maintenance standa...

Page 6: ...or High Error 4 E 4 Code 123 CA123 Charge Air Press Sensor Low Error 6 E 5 Code 131 CA131 Throttle Sensor High Error 8 E 6 Code 132 CA132 Throttle Sensor Low Error 10 E 7 Code 144 CA144 Coolant Temp S...

Page 7: ...hrottle Sens Sup Volt High Error 42 E 50 Code 2186 CA2186 Throttle Sens Sup Volt Low Error 43 E 51 Code 2249 CA2249 Rail Press very Low Error 44 E 52 Code 2265 CA2265 Abnormally high level in electric...

Page 8: ...462 01 General information on disassembly and assembly 2 How to read this manual 2 Coating materials list 3 Special tools list 6 Disassembly and assembly Part 1 SEN00463 01 Disassembly and assembly 2...

Page 9: ...00 Index and foreword SEN00171 05 114E 3 Series 7...

Page 11: ...ual 7 Explanation of terms for maintenance standard 9 Handling of electric equipment and hydraulic component 11 Handling of connectors newly used for engines 20 How to read electric wire code 23 Preca...

Page 12: ...with a grinder etc 4 When carrying out any operation with 2 or more workers always agree on the oper ating procedure before starting Always inform your fellow workers before starting any step of the o...

Page 13: ...ver which is under internal pressure or under pressure from a spring always leave 2 bolts in diagonal positions Loosen those bolts gradually and alternately to release the pressure and then remove the...

Page 14: ...de hanging angle from the hook When hoisting a load with 2 or more ropes the force subjected to each rope will increase with the hanging angle The table below shows the variation of allow able load in...

Page 15: ...ile the slung load is swinging 6 Do not raise or lower a load while the crane is moving longitudinally or laterally 7 Do not drag a sling 8 When lifting up a load stop it just after it leaves the grou...

Page 16: ...illing it you must be quali fied for handling the refrigerant and put on protective goggles 2 Connection 1 When installing the air conditioner cir cuit hoses and tubes take care that dirt dust water e...

Page 17: ...he standard values and judgement criteria for testing and adjusting are explained in Testing and adjusting 40 Troubleshooting This section explains how to find out failed parts and how to repair them...

Page 18: ...ated with International System of units SI For reference con ventionally used Gravitational System of units is indicated in parentheses Symbol Item Remarks k Safety Special safety precautions are nece...

Page 19: ...the range of differ ence from the standard size is called the tolerance q The tolerance with the symbols of or is indicated on the right side of the standard size a The tolerance may be indicated in t...

Page 20: ...that the interference is in the standard range 4 Repair limit and allowable value q The size of a part changes because of wear and deformation while it is used The limit of changed size is called the...

Page 21: ...more likely to be affected by the direct effects of rain water heat or vibration Furthermore during inspection and repair operations they are frequently removed and installed again so they are likely...

Page 22: ...ter does enter it is difficult for it to be drained Therefore if water should get into the connector the pins will be short cir cuited by the water so if any water gets in immediately dry the connecto...

Page 23: ...pull with one hand 2 When removing from clips q Both of the connector and clip have stoppers which are engaged with each other when the connector is installed q When removing a connector from a clip...

Page 24: ...his will cause short circuits a If there is any damage or break age replace the connector 2 Fix the connector securely Align the position of the connector correctly and then insert it securely For con...

Page 25: ...re 1 Push in female connector 2 horizon tally until the lock clicks Arrow 1 2 Since locks a and b may not be set completely push in female connector 2 while moving it up and down until the locks are s...

Page 26: ...n the air may cause defective contact so remove all oil and water from the com pressed air before blowing with air 2 Dry the inside of the connector with a dryer If water gets inside the connector use...

Page 27: ...connect all wiring harness con nectors connected to the controller Fit an arc welding ground close to the welding point 5 Points to remember when troubleshooting electric circuits 1 Always turn the po...

Page 28: ...isassembly and maintenance of hydraulic equipment should be carried out in a specially prepared dustproof workshop and the perfor mance should be checked with special test equipment 3 Sealing openings...

Page 29: ...ew oil and will shorten the life of the hydraulic oil 6 Flushing operations After disassembling and assembling the equip ment or changing the oil use flushing oil to remove the contaminants sludge and...

Page 30: ...ngines Ambient pressure sensor PAMB 125 170 12V140 engines Disconnect connector 1 according to the fol lowing procedure 1 Slide lock L1 to the right 2 While pressing lock L2 pull out connec tor 1 towa...

Page 31: ...the direction of the arrow q 114 engine q 107 engine a If the lock is on the underside use flat head screwdriver 1 since you cannot insert your fingers 2 While pressing up lock C of the connec tor wi...

Page 32: ...Turn housing type Round green connector q 140 engine Example Intake air pressure sensor in intake mani fold CANNON 04 PIM etc 1 Disconnect connector 6 according to the following procedure 1 Turn hous...

Page 33: ...ndicates color of wire by color code Color codes are shown in Table 3 Indicates size of wire by nominal No Size Nominal No is shown in Table 2 Indicates type of wire by symbol Type symbol and material...

Page 34: ...23 d approx 1 0 1 2 1 5 1 9 1 9 2 3 2 4 3 0 Cov er D AVS Standard 2 0 2 2 2 5 2 9 2 9 3 5 3 6 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 Conductor...

Page 35: ...lue White BrW Brown White LY Blue Yellow BrY Brown Yellow O Orange Ch Charcoal P Pink Dg Dark green R Red G Green RB Red Black GB Green Black RG Red Green GL Green Blue RL Red Blue Gr Gray RW Red Whit...

Page 36: ...o use lifting equipment of ample strength q When using forcing screws to remove any components tighten the forcing screws uniformly in turn q Before removing any unit clean the surrounding area and fi...

Page 37: ...the cylinder 100 mm from the end of its stroke 3 Next operate the hydraulic cylinder 3 4 times to the end of its stroke 4 After doing this run the engine at normal speed a When using the machine for t...

Page 38: ...If any part is damaged replace it 2 Check the mounting bolts and nuts of the muffler exhaust pipe and their mounting parts for looseness If any bolt or nut is loosened retighten it 5 Checking muffler...

Page 39: ...ter 3 Fig 1 a The adapter can be pushed in about 3 5 mm a Do not hold rubber cap portion 4 2 After hose joint 2 is pushed into adapter 3 press rubber cap portion 4 against adapter 3 until it clicks Fi...

Page 40: ...e hexag onal portion at the male end Fig 6 2 While holding the condition of Step 1 turn lever 8 to the right clockwise Fig 7 3 While holding the condition of Steps 1 and 2 pull out whole body 7 to dis...

Page 41: ...d Fig 10 2 While holding the condition of Step 1 push cover 10 straight until it contacts contact surface b of the hexagonal por tion at the male end Fig 11 3 While holding the condition of Steps 1 an...

Page 42: ...eter of bolt Width across flats Tightening torque mm mm Nm kgm 6 10 11 8 14 7 1 2 1 5 8 13 27 34 2 8 3 5 10 17 59 74 6 0 7 5 12 19 98 123 10 0 12 5 14 22 153 190 15 5 19 5 16 24 235 285 23 5 29 5 18 2...

Page 43: ...Width across flats Tightening torque Nm kgm mm mm Range Target 02 14 Varies depending on type of connec tor 35 63 3 5 6 5 44 4 5 03 04 20 84 132 8 5 13 5 103 10 5 05 06 24 128 186 13 0 19 0 157 16 0 1...

Page 44: ...2 107 and 114 engine series to the torque below Nominal No of hose Width across flats Tightening torque Nm kgm Taper seal Face seal Range Target Thread size mm Nominal No Number of threads type of thr...

Page 45: ...aper screws a Unless there are special instructions tighten the taper screws unit inch of the 102 107 and 114 engine series to the torque below Thread size Tightening torque inch Nm kgm 1 16 3 1 0 31...

Page 46: ...so divide it by 10 move the decimal point one place to the left to convert it to 55 mm 2 Carry out the same procedure as above to convert 55 mm to 2 165 inches 3 The original value 550 mm was divided...

Page 47: ...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...

Page 48: ...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...

Page 49: ...1 451 1 465 1 479 1 493 1 508 1 522 1 536 1 550 110 1 565 1 579 1 593 1 607 1 621 1 636 1 650 1 664 1 678 1 693 120 1 707 1 721 1 735 1 749 1 764 1 778 1 792 1 806 1 821 1 835 130 1 849 1 863 1 877 1...

Page 50: ...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...

Page 51: ...00 Index and foreword SEN00172 03 114E 3 Series 41...

Page 53: ...0174 02 Engine 1SHOP MANUAL 114E 3 Series 01 Specification 1 Specification and technical data Specification and technical data 2 General 2 Specifications 3 General view 8 Dimensions table 12 Engine pe...

Page 54: ...ne Engine Serial No Applicable machine SAA6D114E 3 PC300 7E0 PC300LC 7E0 PC350 7E0 PC350LC 7E0 PC300 8 PC300LC 8 PC350 8 PC350LC 8 WA430 6 D65EX 15E0 D65PX 15E0 D65WX 15E0 GD655 3E0 GD675 3E0 Hydrauli...

Page 55: ...ht including exhaust pipe mm 1 601 Performance Flywheel horsepower kW HP rpm 194 260 1 950 Gross Max torque Nm kgm rpm 1 129 115 1 450 Gross High idle speed rpm 2 050 50 Low idle speed rpm 1 000 25 Mi...

Page 56: ...including exhaust pipe mm 1 601 Performance Flywheel horsepower kW HP rpm 194 260 1 950 Gross Max torque Nm kgm rpm 1 129 115 1 450 Gross High idle speed rpm 2 050 50 Low idle speed rpm 1 000 25 Min f...

Page 57: ...605 Performance Flywheel horsepower kW HP rpm 173 232 2 100 Gross Max torque Nm kgm rpm 1 020 104 1 450 Gross High idle speed rpm 2 245 50 Low idle speed rpm 765 25 Min fuel consumption ratio g kW h...

Page 58: ...exhaust pipe mm 1 532 Performance Flywheel horsepower kW HP rpm 154 206 1 950 Gross Max torque Nm kgm rpm 1 010 103 1 450 Gross High idle speed rpm 2 030 50 Low idle speed rpm 825 25 Min fuel consumpt...

Page 59: ...haust pipe mm 1 455 Performance Flywheel horsepower kW HP rpm 154 206 1 900 Gross Max torque Nm kgm rpm 990 101 1 450 Gross High idle speed rpm 2 225 50 Low idle speed rpm 825 25 Min fuel consumption...

Page 60: ...Specification General view 1 SAA6D114E 3 Left side view of engine Machine model PC300 7E0 PC300LC 7E0 PC350 7E0 PC350LC 7E0 a The shape may differ according to the machine model 1 Crankshaft center 2...

Page 61: ...ification SEN00174 02 SAA6D114E 3 Right side view of engine Machine model PC300 7E0 PC300LC 7E0 PC350 7E0 PC350LC 7E0 a The shape may differ according to the machine model 1 Crankshaft center 2 Flywhe...

Page 62: ...es SEN00174 02 01 Specification SAA6D114E 3 Front view of engine Machine model PC300 7E0 PC300LC 7E0 PC350 7E0 PC350LC 7E0 a The shape may differ according to the machine model 1 Crankshaft center 2 C...

Page 63: ...11 01 Specification SEN00174 02 SAA6D114E 3 Rear view of engine Machine model PC300 7E0 PC300LC 7E0 PC350 7E0 PC350LC 7E0 a The shape may differ according to the machine model 1 Crankshaft center 2 Cy...

Page 64: ...the engine is set on a test bench Unit mm Engine Machine model Dimension of each part A B C SAA6D114E 3 PC300 7E0 PC300LC 7E0 PC350 7E0 PC350LC 7E0 PC300 8 PC300LC 8 PC350 8 PC350LC 8 1 625 1 601 1 0...

Page 65: ...4 02 Engine performance curves 1 Engine Engine serial No Machine model Page SAA6D114E 3 PC300 7E0 PC300LC 7E0 PC350 7E0 PC350LC 7E0 PC300 8 PC300LC 8 PC350 8 PC350LC 8 14 WA430 6 15 D65EX 15E0 D65PX 1...

Page 66: ...0174 02 01 Specification SAA6D114E 3 1 Machine model PC300 7E0 PC300LC 7E0 PC350 7E0 PC350LC 7E0 PC300 8 PC300LC 8 PC350 8 PC350LC 8 1 Rated output 194 kW 260 HP 1 950 rpm Gross Max torque 1 129 Nm 11...

Page 67: ...114E 3 Series 15 01 Specification SEN00174 02 SAA6D114E 3 Machine model WA430 6 1 Rated output 173 kW 232 HP 2 100 rpm Gross Max torque 1 020 Nm 104 kgm 1 450 rpm Gross...

Page 68: ...16 114E 3 Series SEN00174 02 01 Specification SAA6D114E 3 Machine model D65EX 15E0 D65PX 15E0 D65WX 15E0 Rated output 154 kW 206 HP 1 950 rpm Gross Max torque 1 010 Nm 103 kgm 1 450 rpm Gross...

Page 69: ...114E 3 Series 17 01 Specification SEN00174 02 SAA6D114E 3 Machine model GD655 3E0 GD675 3E0 1 Rated output 154 kW 206 HP 1 900 rpm Gross Max torque 990 Nm 101 kgm 1 450 rpm Gross...

Page 71: ...Lubricating oil system 7 Cooling system 9 Fuel system common rail 10 Maintenance standard 15 Turbocharger 15 Cylinder head 16 Cylinder block 18 Cylinder liner 20 Crankshaft 22 Piston piston ring and...

Page 72: ...ead 5 Intake valve The combustion air system on the engine consists of an air cleaner intake air piping turbocharger charge air piping charge air cooler CAC and intake air heater Air is drawn through...

Page 73: ...cture function and maintenance standard SEN00176 02 114E 3 Series 3 Exhaust system 1 General Information 1 Exhaust valve 2 Exhaust manifold pulse type 3 Dual entry turbocharger 4 Turbocharger exhaust...

Page 74: ...to be injected to increase the power output from the engine The turbine compressor wheels and shaft are sup ported by two rotating bearings in the bearing hous ing Passages in the bearing housing dire...

Page 75: ...e pneumatic actuator 3 operated by an air control valve 4 and receives air from the air supply tank 5 q When the variable geometry turbocharger mechanism opens a noise can be heard as air is released...

Page 76: ...dia phragm and rod As the pressure changes in the canister as dictated by the wastegate controller the actuator rod adjusts the wastegate valve accordingly The wastegate valve is mounted inside the tu...

Page 77: ...bricating oil cooler 3 To lubricating oil pan 4 Full flow lubricating oil filter 5 Filter bypass valve 6 From lubricating oil filter 1 From lubricating oil cooler 2 Main lubricating oil rifle 3 To cam...

Page 78: ...ricating oil supply from filter 2 Turbocharger lubricating oil supply 3 Turbocharger lubricating oil drain 1 From cam bushings 2 Transfer slot 3 Rocker lever support 4 Rocker lever shaft 5 Rocker leve...

Page 79: ...r outlet optional 7 Coolant supply to cylinder head 8 Coolant return from cylinder head 9 Block upper water manifold 10 Thermostat bypass 11 Coolant return to radiator Conventionally cooled engines wi...

Page 80: ...ted fuel lift pump 7 Fuel outlet from ECM mounted fuel lift pump 8 Fuel gear pump 9 Fuel from gear pump to fuel filter 10 Primary fuel filter 11 Fuel inlet to fuel pump actuator 12 High pressure fuel...

Page 81: ...idual solenoids The ECM powers each injector individually to provide fueling to each cylinder The high pressure fuel pump can be divided into four distinct assemblies They are the fuel gear pump fuel...

Page 82: ...mp camshaft through an internal coupling Each of the two pumping plungers is driven by a three lobed camshaft The camshaft is located in the cam housing module by tapered roller bearings The bearings...

Page 83: ...outside of the filter and back up through the middle The filtering media is a 10 micron Stratapore design for efficient debris removal The filter also strips the water and collects it at the bottom of...

Page 84: ...nector pushes against the injector body when the fuel connector nut is tight ened The injector supply line is then connected to the fuel connector The torque and sequence for this joint is critical If...

Page 85: ...ance standard 1 Turbocharger 1 Unit mm No Check item Criteria Remedy 1 Radial play Play in radial direction 0 330 0 508 Replace bearing parts 2 End play Play in axial direction 0 025 0 127 Replace thr...

Page 86: ...SEN00176 02 10 Structure function and maintenance standard 16 114E 3 Series Cylinder head 1...

Page 87: ...g torque for cylinder head mounting bolt Apply molybdenum disulfide or engine oil to threaded part Procedure Target Nm kgm Tighten and retighten 1st stage 150 15 3 2nd stage Loosen 3rd stage 110 11 2...

Page 88: ...SEN00176 02 10 Structure function and maintenance standard 18 114E 3 Series Cylinder block 1...

Page 89: ...Diameter of cam bushing mounting hole Max 64 013 Correct or replace block 4 Inside diameter of cam bushing Max 60 120 Replace cam bushing 5 Tightening torque for main cap mounting bolt Apply engine o...

Page 90: ...SEN00176 02 10 Structure function and maintenance standard 20 114E 3 Series Cylinder liner 1...

Page 91: ...er liner Repair limit 0 04 Taper of cylinder liner Repair limit 0 04 2 Protrusion of cylinder liner 0 026 0 122 Replace cylinder liner or cylinder block 3 Outside diameter of cylinder liner 130 938 13...

Page 92: ...size metal 2 Outside diameter of main journal 76 000 76 026 Use undersize journal or replace Roundness of main journal Repair limit 0 050 Taper of main journal Max 0 013 Clearance of main journal 0 03...

Page 93: ...piston pin 1 Unit mm No Check item Criteria Remedy 1 Clearance at piston ring end gap Top ring 0 30 0 45 Replace piston ring or piston 2nd ring 0 85 1 15 Oil ring 0 30 0 73 2 Outside diameter of pisto...

Page 94: ...SEN00176 02 10 Structure function and maintenance standard 24 114E 3 Series Connecting rod 1...

Page 95: ...aring 76 045 76 095 Replace connect ing rod bearing 3 Thickness of connecting rod bearing 2 459 2 471 4 Inside diameter of connecting rod bearing mounting hole 80 987 81 013 Replace connect ing rod 5...

Page 96: ...02 10 Structure function and maintenance standard 26 114E 3 Series Vibration damper 1 Unit mm No Check item Criteria Remedy 1 Tightening torque of vibration damper Target Nm kgm Tighten and retighten...

Page 97: ...tandard SEN00176 02 114E 3 Series 27 Timing gear 1 Unit mm No Check item Criteria Remedy Backlash of each gear A Backlash of oil pump gear 0 08 0 33 Replace B Backlash of camshaft gear 0 08 0 33 C Bac...

Page 98: ...No Check item Criteria Remedy 1 End play 0 12 0 50 Replace thrust plate 2 Outside diameter of camshaft bearing journal 59 962 60 013 Correct or replace 3 Thickness of camshaft thrust plate 9 40 9 60 R...

Page 99: ...10 Structure function and maintenance standard SEN00176 02 114E 3 Series 29...

Page 100: ...SEN00176 02 10 Structure function and maintenance standard 30 114E 3 Series Valve and valve guide 1...

Page 101: ...ckness B of valve head Intake Min 2 20 Replace Exhaust Min 1 83 3 Angle of valve seat Valve Angle Repair limit Correct or replace valve valve seat Intake 30 Judge condition of contact surface with vac...

Page 102: ...SEN00176 02 10 Structure function and maintenance standard 32 114E 3 Series Rocker arm shaft and tappet 1...

Page 103: ...ole Max 22 027 Replace rocker arm 3 Clearance between rocker arm shaft and rocker arm Max 0 062 Replace rocker arm or shaft 4 Tightening torque of locknut for rocker arm adjustment screw Target Nm kgm...

Page 104: ...SEN00176 02 10 Structure function and maintenance standard 34 114E 3 Series Flywheel and flywheel housing 1...

Page 105: ...using Repair limit 0 20 3 Tightening torque of flywheel housing mounting bolt Target Nm kgm Tighten 77 7 85 4 Face runout of flywheel Flywheel Limit Reassemble correct For clutch 0 013 25 4 For torque...

Page 106: ...Check item Criteria Remedy 1 Clearance of rotor in axial direction 0 025 0 127 Replace oil pump 2 Clearance between outer rotor and body 0 178 0 381 3 Clearance between outer rotor and inner rotor 0 0...

Page 107: ...10 Structure function and maintenance standard SEN00176 02 114E 3 Series 37...

Page 109: ...ngine 1SHOP MANUAL 114E 3 Series 20 Standard value table Standard service value table Standard service value table 2 Standard value table for testing adjusting and troubleshooting 2 Run in standard an...

Page 110: ...t 20 C C Max 600 Max 650 Exhaust gas color At rated horsepower Max 1 0 Max 2 0 Quick acceleration Low idle o high idle Max 25 Max 35 Valve clearance Intake valve mm 0 305 0 152 0 559 Exhaust valve mm...

Page 111: ...Quick acceleration Low idle o high idle Max 25 Max 35 Valve clearance Intake valve mm 0 305 0 152 0 559 Exhaust valve mm 0 559 0 381 0 813 Engine body Compression pressure Oil temperature 40 60 C MPa...

Page 112: ...1 0 Max 2 0 Quick acceleration Low idle o high idle Max 25 Max 35 Valve clearance Intake valve mm 0 305 0 152 0 559 Exhaust valve mm 0 559 0 381 0 813 Engine body Compression pressure Oil temperature...

Page 113: ...2 0 Quick acceleration Low idle o high idle Max 25 Max 35 Valve clearance Intake valve mm 0 305 0 152 0 559 Exhaust valve mm 0 559 0 381 0 813 Engine body Compression pressure Oil temperature 40 60 C...

Page 114: ...6D114E 3 Applicable machine PC300 300LC 7E0 PC350 350LC 7E0 PC300 300LC 8 PC350 350LC 8 Item Procedure 1 2 3 4 5 Running time min 2 10 2 3 10 Engine speed rpm 1 000 1 000 1 200 1 600 1 950 Dynamometer...

Page 115: ...e min 2 10 2 3 10 Engine speed rpm 765 1 000 1 200 1 600 2 100 Dynamometer load N kg 0 0 98 10 245 25 637 65 1 097 112 Output kW HP 0 0 7 4 10 22 29 5 76 102 173 232 Engine SAA6D114E 3 Applicable mach...

Page 116: ...e min 2 10 2 3 10 Engine speed rpm 825 1 000 1 200 1 600 1 950 Dynamometer load N kg 0 0 98 10 245 25 637 65 1 058 108 Output kW HP 0 0 7 4 10 22 29 5 76 102 154 206 Engine SAA6D114E 3 Applicable mach...

Page 117: ...ime min 2 10 2 3 10 Engine speed rpm 825 1 000 1 200 1 600 1 900 Dynamometer load N kg 0 0 98 10 245 25 637 65 1 090 111 Output kW HP 0 0 7 4 10 22 29 5 76 102 154 206 Engine SAA6D114E 3 Applicable ma...

Page 119: ...Testing compression pressure 7 Testing blow by pressure 10 Testing oil pressure 11 Handling fuel system parts 12 Releasing residual pressure in fuel system 12 Testing fuel pressure 13 Reduced cylinder...

Page 120: ...SEN00455 01 30 Testing and adjusting 2 114E 3 Series Replacing alternator belt 23...

Page 121: ...215 81 9710 O ring 1 3 799 401 2320 Gauge 1 Pressure gauge 1 MPa 10 kg cm2 4 795 790 6210 M10 computer check fitting 1 5 795 790 1500 Fuel vacuum gauge 1 Male 7 8 14UNF female 7 8 14UNF Male 3 4 16UNF...

Page 122: ...ple 1 and hose 2 of boost gauge kit A and connect it to gauge 3 3 Run the engine at the rated output and test the air boost pressure a When testing with the engine mounted on the machine test on the c...

Page 123: ...te it forward a Alternatively you may fit a claw bar 1 on the bolts at the end of the crankshaft pulley 6 and rotate it 2 Align the TDC stamp line a of gear cover 7 with stamp line b of the supply pum...

Page 124: ...that you can move the clearance gauge C2 lightly 3 Fix adjustment screw 11 and tighten locknut 10 3 Locknut 24 4 Nm 2 45 0 41 kgm a After tightening the locknut check the valve clearance again 4 Rota...

Page 125: ...jector harness connectors 4 at 6 places and move the harnesses 3 Disconnect fuel high pressure tube 5 4 Loosen injector terminal nut 6 and remove the terminal from the injector 5 Move the cylinder to...

Page 126: ...uring testing and will be dangerous Accord ingly be sure to set the engine in this mode 16 Rotate the engine with the starting motor and measure the compression pressure a Read the pressure gauge poin...

Page 127: ...etainer 10 and the cylinder head 2 Caulking compound GE TOSHIBA SILICON TOSSEAL 381 9 Install the fuel high pressure piping 5 3 Sleeve nut 37 3 4 Nm 3 8 0 4 kgm 10 Install the rocker arm assembly 6 a...

Page 128: ...ow by pressure a The test point is subject to machine models 1 Install adapter 1 of blow by checker E to the tip of blow by hose 1 2 Connect hose 2 and then connect it to adapter 1 and gauge 3 3 Run t...

Page 129: ...of hydraulic tester F1 to nip ple 1 and gauge F2 4 Run the engine at the rated output and low idle and test the oil pressure a When testing with the engine mounted on the machine test on the condition...

Page 130: ...ring it If a filter other than the genuine one is used the fuel system may have a trouble Accordingly never use such a filter Releasing residual pressure in fuel system 1 a Pressure is generated in th...

Page 131: ...ng G4 to fuel vacuum gauge G5 3 Run the engine at high idle and test the fuel negative pressure circuit pressure a If the fuel negative pressure circuit pressure is in the following range it is normal...

Page 132: ...fuel low pressure circuit pressure fuel filter inlet side 1 Remove fuel pressure pickup plug 3 from the fuel main filter inlet side 2 Install adapter G2 and nipple 1 of hydraulic tester G1 and connec...

Page 133: ...finishing testing remove the testing tools and return the removed parts 3 Fuel pressure pickup plug 20 22 Nm 2 0 2 2 kgm 5 Testing difference of pressure in front and rear part of fuel filter 1 Remove...

Page 134: ...7 on the back side of engine controller 6 a The fuel lift pump operates for 30 seconds after the starting switch is turned ON and then stops Measure the pressure while the pump is operating a If the f...

Page 135: ...t in the standard range while fuel is in the fuel lift pump remove check valve 8 of engine controller cooling plate 7 and check to see if the valve is seized 4 After finishing measurement remove the m...

Page 136: ...Since the common rail fuel injection system controls the injector of each cylinder electroni cally the operator can perform the reduced cyl inder mode operation easily with switches to find out a defe...

Page 137: ...g cm2 6 Run the engine at low idle and test the return rate from the supply pump a If the return rate from the supply pump is in the following range it is normal k When the engine cannot run you may t...

Page 138: ...nect adapter H2 to the return tube joint connecting part at the cylinder block side to block fuel leakage 4 Connect INSITE troubleshooting kit to the engine and set it so that it can check the engine...

Page 139: ...n fuel is not available do not remove the fuel pre filter but fill it with the fuel by operating priming pump a Do not add fuel to fuel main filter 1 from outside 3 Fill up the fuel tank with fuel 4 K...

Page 140: ...f any fuel leakage is detected repair it and inspect again from step 2 4 Run the engine at low idle 5 Inspect the fuel piping and devices for fuel leakage a Check mainly around the high pressure circu...

Page 141: ...is inserted in or connected to a connector related to the high voltage circuit for troubleshooting do not start the engine a You may turn the starting switch to the OFF or ON position but must not tur...

Page 143: ...GINE 1SHOP MANUAL 114E 3 Series 40 Troubleshooting 1 General information on troubleshooting General information on troubleshooting 2 Points on troubleshooting 2 Error and failure code table 3 Informat...

Page 144: ...se the confidence of the user or operator For this reason when carrying out troubleshooting it is necessary to carry out thorough prior investigation and to carry out troubleshooting in accordance wit...

Page 145: ...peed 238 CA238 Ne Speed Sensor Sup Volt Error 271 CA271 IMV IMA Short Error 272 CA272 IMV IMA Open Error 281 CA281 High pressure pump error 322 CA322 Injector No 1 System Open Short Error 323 CA323 In...

Page 146: ...kup Speed Sensor Phase Error 757 CA757 All Engine Controller Data Lost Error 778 CA778 Eng Bkup Speed Sensor Error 1633 CA1633 KOMNET Error 2185 CA2185 Throttle Sens Sup Volt High Error 2186 CA2186 Th...

Page 147: ...40 Troubleshooting SEN00457 01 114E 3 Series 5...

Page 148: ...state to judge possible causes Remarks on judgment Troubles in wiring harness Disconnection Connector is connected imperfectly or wiring harness is broken Ground fault Wiring harness which is not con...

Page 149: ...Troubleshooting SEN00457 01 114E 3 Series 7 Related circuit diagram This drawing is a part of the electric circuit diagram related to troubleshooting Connector No Indicates Model Number of pins and Co...

Page 151: ...h Error 4 E 4 Code 123 CA123 Charge Air Press Sensor Low Error 6 E 5 Code 131 CA131 Throttle Sensor High Error 8 E 6 Code 132 CA132 Throttle Sensor Low Error 10 E 7 Code 144 CA144 Coolant Temp Sensor...

Page 152: ...E 19 Code 272 CA272 IMV IMA Open Error 32 E 20 Code 281 CA281 High pressure pump error 34 E 21 Code 322 CA322 Injector No 1 System Open Short Error 36 E 22 Code 323 CA323 Injector No 5 System Open Sho...

Page 153: ...n normal state Causes Standard value in normal state Remarks on troubleshooting 1 Defective engine controller Carry out troubleshooting for failure code CA757 Error code Failure code Trouble Abnormali...

Page 154: ...oltage is measured with wiring harness connected Accordingly if voltage is abnormal check wiring harness and controller too for another cause of trouble and then judge 3 Hot short Short circuit with 5...

Page 155: ...40 Troubleshooting SEN00459 01 114E 3 Series 5 Circuit diagram related to boost pressure temperature sensor combination sensor...

Page 156: ...e is measured with wiring harness connected Accordingly if voltage is abnormal check wiring harness and controller too for another cause of trouble and then judge 3 Ground fault in wiring har ness Sho...

Page 157: ...40 Troubleshooting SEN00459 01 114E 3 Series 7 Circuit diagram related to boost pressure temperature sensor combination sensor...

Page 158: ...connected Accordingly if voltage is abnormal check wiring harness and controller too for another cause of trouble and then judge 3 Hot short Short circuit with 5 V 24 V circuit in wiring har ness aPre...

Page 159: ...40 Troubleshooting SEN00459 01 114E 3 Series 9 Circuit diagram related to fuel control dial...

Page 160: ...ed Accordingly if voltage is abnormal check wiring harness and controller too for another cause of trouble and then judge 3 Ground fault in wiring har ness Short circuit with GND circuit aPrepare with...

Page 161: ...40 Troubleshooting SEN00459 01 114E 3 Series 11 Circuit diagram related to fuel control dial...

Page 162: ...ring or defective contact in con nector aPrepare with starting switch OFF then carry out troubleshooting without turning starting switch ON Wiring harness between J1 female 15 COOLANT TEMP female B Re...

Page 163: ...40 Troubleshooting SEN00459 01 114E 3 Series 13 Circuit diagram related to coolant temperature sensor...

Page 164: ...round fault in wiring har ness Short circuit with GND circuit aPrepare with starting switch OFF then carry out troubleshooting without turning starting switch ON Wiring harness between J1 female 15 CO...

Page 165: ...40 Troubleshooting SEN00459 01 114E 3 Series 15 Circuit diagram related to coolant temperature sensor...

Page 166: ...ction in wiring har ness Disconnection in wiring or defective contact in con nector aPrepare with starting switch OFF then carry out troubleshooting without turning starting switch ON Wiring harness b...

Page 167: ...40 Troubleshooting SEN00459 01 114E 3 Series 17 Circuit diagram related to boost pressure temperature sensor combination sensor...

Page 168: ...ween 3 chassis ground All range Min 100 kz 2 Ground fault in wiring har ness Short circuit with GND circuit aPrepare with starting switch OFF then carry out troubleshooting without turning starting sw...

Page 169: ...40 Troubleshooting SEN00459 01 114E 3 Series 19 Circuit diagram related to boost pressure temperature sensor combination sensor...

Page 170: ...oblem that appears on machine Engine stops Output drops Related infor mation Possiblecauses and standard value in normal state Causes Standard value in normal state Remarks on troubleshooting 1 Drop i...

Page 171: ...40 Troubleshooting SEN00459 01 114E 3 Series 21...

Page 172: ...nnect connector with starting switch OFF then turn starting switch ON and carry out troubleshooting Disconnect devices at right in order If mark E of failure code dis appears after repro duction opera...

Page 173: ...40 Troubleshooting SEN00459 01 114E 3 Series 23 Circuit diagram related to sensor power supply 2...

Page 174: ...wiring harness connected Accordingly if voltage is abnormal check wiring harness and controller too for another cause of trouble and then judge 3 Hot short Short circuit with 5V 24V circuit in wiring...

Page 175: ...40 Troubleshooting SEN00459 01 114E 3 Series 25 Circuit diagram related to atmospheric pressure sensor...

Page 176: ...wiring harness connected Accordingly if voltage is abnormal check wiring harness and controller too for another cause of trouble and then judge 3 Ground fault in wiring har ness Short circuit with GN...

Page 177: ...40 Troubleshooting SEN00459 01 114E 3 Series 27 Circuit diagram related to atmospheric pressure sensor...

Page 178: ...ppears on machine Engine output drops Related infor mation Method of reproducing failure code Starting switch ON Possiblecauses and standard value in normal state Causes Standard value in normal state...

Page 179: ...ngine speed fluctuates Related infor mation Method of reproducing failure code Start engine and run it at high idle Possiblecauses and standard value in normal state Causes Standard value in normal st...

Page 180: ...sible causes and standard value in normal state Causes Standard value in normal state Remarks on troubleshooting 1 Defective sensor or wiring harness aDisconnect connector with starting switch OFF the...

Page 181: ...ound Min 100 kz 2 Ground fault in wiring har ness Short circuit with GND circuit aPrepare with starting switch OFF then carry out troubleshooting without turning starting switch ON Wiring harness betw...

Page 182: ...ing harness between J1 female 2 CP3 PUMP REGULATOR female 1 Resis tance Max 10 z Wiring harness between J1 female 32 CP3 PUMP REGULATOR female 2 Resis tance Max 10 z 3 Hot short Short circuit with 24V...

Page 183: ...40 Troubleshooting SEN00459 01 114E 3 Series 33 Circuit diagram related to supply pump actuator metering unit...

Page 184: ...re code Start engine Possiblecauses and standard value in normal state Causes Standard value in normal state Remarks on troubleshooting 1 Air in fuel circuit Bleed air from the fuel circuit See Testin...

Page 185: ...40 Troubleshooting SEN00459 01 114E 3 Series 35...

Page 186: ...2 z 3 Ground fault in wiring har ness Short circuit with GND circuit aPrepare with starting switch OFF then carry out troubleshooting without turning starting switch ON Wiring harness between J1 fema...

Page 187: ...40 Troubleshooting SEN00459 01 114E 3 Series 37 Circuit diagram related to injector No 1...

Page 188: ...2 z 3 Ground fault in wiring har ness Short circuit with GND circuit aPrepare with starting switch OFF then carry out troubleshooting without turning starting switch ON Wiring harness between J1 fema...

Page 189: ...40 Troubleshooting SEN00459 01 114E 3 Series 39 Circuit diagram related to injector No 5...

Page 190: ...2 z 3 Ground fault in wiring har ness Short circuit with GND circuit aPrepare with starting switch OFF then carry out troubleshooting without turning starting switch ON Wiring harness between J1 fema...

Page 191: ...40 Troubleshooting SEN00459 01 114E 3 Series 41 Circuit diagram related to injector No 3...

Page 192: ...Ground fault in wiring har ness Short circuit with GND circuit aPrepare with starting switch OFF then carry out troubleshooting without turning starting switch ON Wiring harness between J1 female 57...

Page 193: ...40 Troubleshooting SEN00459 01 114E 3 Series 43 Circuit diagram related to injector No 6...

Page 194: ...2 z 3 Ground fault in wiring har ness Short circuit with GND circuit aPrepare with starting switch OFF then carry out troubleshooting without turning starting switch ON Wiring harness between J1 fema...

Page 195: ...40 Troubleshooting SEN00459 01 114E 3 Series 45 Circuit diagram related to injector No 2...

Page 196: ...2 z 3 Ground fault in wiring har ness Short circuit with GND circuit aPrepare with starting switch OFF then carry out troubleshooting without turning starting switch ON Wiring harness between J1 fema...

Page 197: ...40 Troubleshooting SEN00459 01 114E 3 Series 47 Circuit diagram related to injector No 4...

Page 198: ...None in particular Problem that appears on machine Normal operation or engine stops and engine cannot be started Related infor mation Method of reproducing failure code Starting switch ON Possible ca...

Page 199: ...40 Troubleshooting SEN00459 01 114E 3 Series 49...

Page 201: ...olt High Error 7 E 31 Code 428 CA428 Water Sensor High Level Error 8 E 32 Code 429 CA429 Water Sensor Low Level Error 10 E 33 Code 431 CA431 Idle Validation Switch Error 12 E 34 Code 432 CA432 Idle Va...

Page 202: ...ror 40 E 49 Code 2185 CA2185 Throttle Sens Sup Volt High Error 42 E 50 Code 2186 CA2186 Throttle Sens Sup Volt Low Error 43 E 51 Code 2249 CA2249 Rail Press very Low Error 44 E 52 Code 2265 CA2265 Abn...

Page 203: ...Defective fuse No 19 If fuse is burnt out circuit probably has ground fault 3 Defective relay for engine controller power supply aPrepare with starting switch OFF then turn starting switch ON and car...

Page 204: ...SEN00460 01 40 Troubleshooting 4 114E 3 Series Circuit diagram related to engine controller power supply...

Page 205: ...ring harness aDisconnect connector with starting switch OFF then turn starting switch ON and carry out troubleshooting Disconnect devices at right in order If mark E of failure code dis appears after...

Page 206: ...SEN00460 01 40 Troubleshooting 6 114E 3 Series Circuit diagram related to sensor power supply 1...

Page 207: ...poor Related infor mation Method of reproducing failure code Starting switch ON Possible causes and standard value in normal state Causes Standard value in normal state Remarks on troubleshooting 1 De...

Page 208: ...ector aPrepare with starting switch OFF then carry out troubleshooting without turning starting switch ON Wiring harness between J1 female 14 P47 male 1 Resis tance Max 10 z Wiring harness between J1...

Page 209: ...40 Troubleshooting SEN00460 01 114E 3 Series 9 Circuit diagram related to water in fuel sensor...

Page 210: ...rcuit with GND circuit aPrepare with starting switch OFF then carry out troubleshooting without turning starting switch ON Wiring harness between J1 female 14 P47 male 1 Resis tance Min 100 kz 3 Short...

Page 211: ...40 Troubleshooting SEN00460 01 114E 3 Series 11 Circuit diagram related to water in fuel sensor...

Page 212: ...arry out troubleshooting without turning starting switch ON Wiring harness between J2 female 11 WAS1 female 5 Resis tance Max 10 z Wiring harness between J2 female 1 WAS1 female 6 Resis tance Max 10 z...

Page 213: ...40 Troubleshooting SEN00460 01 114E 3 Series 13 Circuit diagram related to accelerator pedal...

Page 214: ...n con nector aPrepare with starting switch OFF then carry out troubleshooting without turning starting switch ON Wiring harness between J2 female 22 WAS1 female 1 Resis tance Max 10 z Wiring harness b...

Page 215: ...40 Troubleshooting SEN00460 01 114E 3 Series 15 Circuit diagram related to accelerator pedal...

Page 216: ...onnection in wiring har ness Disconnection in wiring or defective contact in con nector aPrepare with starting switch OFF then carry out troubleshooting without turning starting switch ON Wiring harne...

Page 217: ...40 Troubleshooting SEN00460 01 114E 3 Series 17...

Page 218: ...in wiring or defective contact in con nector aPrepare with starting switch OFF then carry out troubleshooting without turning starting switch ON Wiring harness between F01 19 R23 R24 female 3 Resis ta...

Page 219: ...causes and standard value in normal state Causes Standard value in normal state Remarks on troubleshooting 9 Defective engine controller aPrepare with starting switch OFF then turn starting switch ON...

Page 220: ...causes and standard value in normal state Causes Standard value in normal state Remarks on troubleshooting 1 Defective battery voltage aPrepare with starting switch OFF then carry out troubleshooting...

Page 221: ...40 Troubleshooting SEN00460 01 114E 3 Series 21 Circuit diagram related to engine controller power supply...

Page 222: ...uit device aFor check of pressure in fuel low pressure circuit see Testing and adjusting Testing fuel pressure Measure at fuel filter outlet side Pressure in fuel low pressure circuit At high idle Whe...

Page 223: ...tch OFF connect INSITE then start engine and carry out troubleshooting Measure after running engine at idle at least 1 minute Monitoring on INSITE Monitoring information Common rail pressure At low id...

Page 224: ...harness connected Accordingly if voltage is abnormal check wiring harness and controller too for another cause of trouble and then judge 3 Hot short Short circuit with 5 V 24 V circuit in wiring har n...

Page 225: ...40 Troubleshooting SEN00460 01 114E 3 Series 25 Circuit diagram related to common rail pressure sensor...

Page 226: ...ess connected Accordingly if voltage is abnormal check wiring harness and controller too for another cause of trouble and then judge 3 Ground fault in wiring har ness Short circuit with GND circuit aP...

Page 227: ...40 Troubleshooting SEN00460 01 114E 3 Series 27 Circuit diagram related to common rail pressure sensor...

Page 228: ...s on machine Output drops Related infor mation Method of reproducing failure code Start engine Possiblecauses and standard value in normal state Causes Standard value in normal state Remarks on troubl...

Page 229: ...rops Related infor mation Method of reproducing failure code Start engine Possiblecauses and standard value in normal state Causes Standard value in normal state Remarks on troubleshooting 1 Defective...

Page 230: ...and adjusting Testing fuel pressure Measure at fuel filter outlet side Pressure in fuel low pressure circuit At high idle Min 0 48 MPa Min 4 9 kg cm2 aFor check of pressure in fuel low pressure circu...

Page 231: ...kage from pressure limiter and return rate from injector Leakage from pressure limiter At low idle Below 30 drops 60 sec 6 Defects in supply pump plunger aRemove supply pump head and inspect plunger f...

Page 232: ...y 5 Disconnection in wiring har ness Disconnection in wiring or defective contact in con nector aPrepare with starting switch OFF then carry out troubleshooting without turning starting switch ON Wiri...

Page 233: ...sor Possible causes and standard value in normal state Causes Standard value in normal state Remarks on troubleshooting 10 Defective engine controller aPrepare with starting switch OFF then turn start...

Page 234: ...directly 3 Defective or broken mount of rotation sensing ring on crankshaft side Inspect it for defect or breakage according to the following proce dure 1 Set No 1 cylinder to compression top dead ce...

Page 235: ...40 Troubleshooting SEN00460 01 114E 3 Series 35...

Page 236: ...urnt out circuit probably has ground fault 5 Defective relay for engine controller power supply aPrepare with starting switch OFF then turn starting switch ON and carry out troubleshooting Replace rel...

Page 237: ...40 Troubleshooting SEN00460 01 114E 3 Series 37 Circuit diagram related to engine controller power supply...

Page 238: ...ctly 5 Disconnection in wiring har ness Disconnection in wiring or defective contact in con nector aPrepare with starting switch OFF then carry out troubleshooting without turning starting switch ON W...

Page 239: ...nsor Possible causes and standard value in normal state Causes Standard value in normal state Remarks on troubleshooting 10 Defective engine controller aPrepare with starting switch OFF then turn star...

Page 240: ...Resis tance Max 1 z Wiring harness between CM02 female 10 C01 female 64 J2 female 47 K02 female B Resis tance Max 1 z 2 Ground fault in wiring har ness Short circuit with GND circuit aPrepare with sta...

Page 241: ...40 Troubleshooting SEN00460 01 114E 3 Series 41 Circuit diagram related to CAN communication...

Page 242: ...ort circuit in wiring har ness With another wiring harness aTroubleshoot with starting switch OFF then carry out trouble shooting without turning starting switch ON Wiring harness among all pins betwe...

Page 243: ...starting switch OFF then carry out trouble shooting without turning starting switch ON Wiring harness between J2 female 22 P20 female 1 Resis tance Min 100 kz 2 Short circuit in wiring har ness With a...

Page 244: ...rred in common rail circuit Action of con troller Limits output and continues operation Problem that appears on machine Starting performance is poor Exhaust smoke is black Output drops Related infor m...

Page 245: ...40 Troubleshooting SEN00460 01 114E 3 Series 45...

Page 246: ...g starting switch ON Wiring harness between J1 female 1 LIFT PUMP female 1 Resis tance Max 10 z Wiring harness between J1 female 11 LIFT PUMP female 2 Resis tance Max 10 z 3 Hot short Short circuit wi...

Page 247: ...40 Troubleshooting SEN00460 01 114E 3 Series 47 Circuit diagram related to electric lift pump actuator...

Page 248: ...turning starting switch ON Wiring harness between J1 female 1 LIFT PUMP female 1 Resis tance Max 100 kz 3 Hot short in wiring harness Short circuit with 24 V cir cuit aPrepare with starting switch OFF...

Page 249: ...40 Troubleshooting SEN00460 01 114E 3 Series 49 Circuit diagram related to electric lift pump actuator...

Page 250: ...onnection in wiring or defective contact in con nector aPrepare with starting switch OFF then carry out troubleshooting without turning starting switch ON Wiring harness between J1 female 2 CP3 PUMP R...

Page 251: ...40 Troubleshooting SEN00460 01 114E 3 Series 51 Circuit diagram related to supply pump actuator metering unit...

Page 252: ...relay R18 with other relay If mark E of fail ure code disappears after reproduction operation is conducted that relay has a defect 2 Disconnection in wiring har ness Disconnection in wiring or defect...

Page 253: ...40 Troubleshooting SEN00460 01 114E 3 Series 53 Circuit diagram related to preheating starting and charging engine...

Page 254: ...Test by replacing relay unit Replace auto preheat relay R18 with other relay If mark E of fail ure code disappears after reproduction operation is conducted that relay has a defect 2 Ground fault in w...

Page 255: ...40 Troubleshooting SEN00460 01 114E 3 Series 55 Circuit diagram related to preheating starting and charging engine...

Page 256: ...ooting on machine side This fault is indicated on only machine side when detected Accordingly contents of troubleshooting depend on machine model See Shop manual for machine Error code Failure code Tr...

Page 257: ...roller Limits output and continues operation Problem that appears on machine Output drops Related infor mation Possible causes and standard value in normal state Causes Standard value in normal state...

Page 259: ...not start 7 S 3 Engine does not pick up smoothly 10 S 4 Engine stops during operations 11 S 5 Engine does not rotate smoothly 12 S 6 Engine lacks output or lacks power 13 S 7 Exhaust smoke is black in...

Page 260: ...8 01 40 Troubleshooting 2 114E 3 Series S 13 Oil level rises Entry of coolant or fuel 20 S 14 Coolant temperature becomes too high overheating 21 S 15 Abnormal noise is made 22 S 16 Vibration is exces...

Page 261: ...m the user or operator depending on their level Check items Items to be simply checked by the serviceman to narrow down causes They correspond to C in the chart on the right Causes Items to be narrowe...

Page 262: ...ust smoke is black Let us assume that Clogged air cleaner is taken to be the cause of black exhaust gas 3 symptoms have causal relationship with this problem Color of exhaust gas gradually became blac...

Page 263: ...58 01 114E 3 Series 5 If we look from these 3 symptoms to find the causes we find that there is a relationship with 5 causes Let us explain here the method of using this causal relationship to pinpoin...

Page 264: ...w When engine is preheated or when temperature is low preheating monitor does not indicate normally if installed w During operation charge level monitor indicates abnormal charge if monitor is instal...

Page 265: ...re is no operating sound from battery relay Q w Check items When starting switch is turned to START starting pinion does not move out Q Q w When starting switch is turned to START starting pinion move...

Page 266: ...hen starting again w Q w w E Replacement of filters has not been carried out according to Operation and Maintenance Manual w E Q When fuel tank is inspected it is found to be empty w Air breather hole...

Page 267: ...r is installed w Dust indicator is red if indicator is installed w Air breather hole of fuel tank cap is clogged Q Rust and water are found when fuel tank is drained w When fuel filter is removed ther...

Page 268: ...be added more frequently w Dust indicator is red if indicator is installed w Air breather hole of fuel tank cap is clogged w Rust and water are found when fuel tank is drained w Fuel is leaking from f...

Page 269: ...slowly w Q There was hunting and engine stopped w Q Q Q Non specified fuel is being used Q Q Q Replacement of filters has not been carried out according to Operation and Maintenance Manual w Fuel lev...

Page 270: ...long period E Condition of hunting Occurs at a certain speed range Q Q Occurs at low idle Q Q Q Q Q Occurs even when speed is raised Q Q Q Occurs on slopes w Replacement of filters has not been carri...

Page 271: ...e added more frequently Q Q Dust indicator is red if indicator is installed w w Air breather hole of fuel tank cap is clogged w Fuel is leaking from fuel piping w Output becomes insufficient after sho...

Page 272: ...Dust indicator is red if indicator is installed w Muffler is crushed w Air leaks between turbocharger and cylinder head clamp is loosened w Check items Engine is operated in low temperature mode at no...

Page 273: ...E E E Oil consumption suddenly increased w Q Oil must be added more frequently w Q Oil becomes contaminated quickly Q Q w Outside of engine is dirty with oil w w w w w There are loose piping clamps in...

Page 274: ...pair history Degree of use of machine Operated for long period E E E Non specified fuel is being used Q Q Oil must be added more frequently w Metal particles are found when oil filter is drained Q Q w...

Page 275: ...adually increased Q Q Suddenly increased Q Q There is external leakage of fuel from engine w Combustion is irregular w Engine oil level rises and oil smells of diesel fuel w w Check items When exhaust...

Page 276: ...ory Degree of use of machine Operated for long period E E Oil level Suddenly rose Q Q Q Gradually rose Q Q Hard water is being used as coolant Q Q Oil level has risen and oil is milky Q Q w Check item...

Page 277: ...filters has not been carried out according to Operation and Mainte nance Manual w Oil pressure monitor if installed Indicates pressure drop at low idle w Indicates pressure drop at low high idle Q w w...

Page 278: ...Coolant must be added more frequently Q Q There is oil in coolant Q Q Q Q w Oil smells of diesel fuel w w Oil is milky Q Q When engine is started drops of water come from muffler Q Check items When ra...

Page 279: ...sion is low w Check items When fan pulley is turned it has play w Milky oil is floating on coolant w There are excessive air bubbles in radiator coolant spurts back w When light bulb is held behind ra...

Page 280: ...achine Operated for long period E Abnormal noise Gradually occurred Q Q Suddenly occurred Q Q Q Non specified fuel is being used Q Oil must be added more frequently w Metal particles are found when oi...

Page 281: ...ns Confirm recent repair history Degree of use of machine Operated for long period E E E Condition of vibration Suddenly increased Q Q Gradually increased Q Q Q Non specified oil is being used Q Q Met...

Page 283: ...GINE 1SHOP MANUAL 114E 3 Series 50 Disassembly and assembly1 General information on disassembly and assembly General information on disassembly and assembly 2 How to read this manual 2 Coating materia...

Page 284: ...lows k Precautions related to safety in execution of work a Know how or precautions for work 6 Quantity of oil or coolant drained 4 Weight of part or component Assembly q In Assembly section the work...

Page 285: ...sed to repair engines ThreeBond 1735 790 129 9140 50 g Polyethylene container Quick setting adhesive Setting time Within 5 sec to 3 min Used mainly to stick metals rubbers plastics and woods Aron alph...

Page 286: ...haust manifold and the turbo charger etc Grease G2 LI G0 LI For cold district SYG2 400LI SYG2 350LI SYG2 400LI A SYG2 160LI SYGA 160CNLI SYG0 400LI A SYG0 160CNLI Various Various Feature Lithium greas...

Page 287: ...NE SEAL 580 SUPER S or W 417 926 3910 320 ml Polyethylene container Adhesive for cab glass S is used for high temperature season and W for low temperature season as adhesive for glass Using limit 4 mo...

Page 288: ...epair stand t 1 795 799 1150 B Adapter t 1 Special for KOMATSU repair stand 795 799 2280 Special for CUMMINS repair stand Removal and installation of air intake valve and exhaust valve C 795 102 2103...

Page 289: ...ler q 1 Rotating crankshaft V 795 799 1131 Barring tool q 1 Tightening injector wiring harness nut W 795 799 7110 Torque wrench q 1 Measuring cylinder head bolt length X 795 790 2210 Gauge q 1 Install...

Page 291: ...114E 3 Series 1 SEN00463 01 ENGINE 1SHOP MANUAL 114E 3 Series 50 Disassembly and assembly1 Disassembly and assembly Part 1 Disassembly and assembly 2 General disassembly of engine 2...

Page 292: ...e the openings electric parts and wiring connectors so that water will not enter them q Prepare stable engine stands Blocks 1 and secure engine assembly 1 on them so that it will not tip over 1 Remove...

Page 293: ...o the opposite to the winding up direction to decrease the alternator belt 1 tension k Make sure that the wrench is secured at the portion A before rotating it The spring of the ten sioner assembly 2...

Page 294: ...1 2 Remove coolant inlet connector 2 10 Thermostat Remove thermostat 1 11 Electrical intake air heater and air intake connector 1 Remove 4 bolts 1 and air intake connec tor assembly 2 2 Remove electr...

Page 295: ...nt bolt of fuel drain tube 1 2 Remove mounting bolt 3 and common rail 2 14 Removal of low pressure hose k The internal parts of the adapter may be damaged when the hose is removed Accordingly do not r...

Page 296: ...1 18 Fuel lift pump and main controller cooling plate Remove fuel lift pump 3 on the back side of main controller cooling plate 2 19 Fuel supply pump 1 Remove cap 1 of the front gear cover 2 Rotate th...

Page 297: ...an excessive force will not be applied to the push rod when the rocker arm is installed 2 Remove crosshead 3 a Record the position of each cross head and the shapes of holes a and b 21 Fuel injector...

Page 298: ...pull up injector 7 a Do not pry up the injector top 22 Push rod Remove 12 push rods 1 23 Rocker housing assembly Remove 7 bolts 2 and rocker housing assem bly 1 24 Turbocharger and exhaust manifold 1...

Page 299: ...and cylinder head assem bly 2 4 Cylinder head assembly 85 kg q Disassemble the cylinder head assembly according to the following procedure 1 Using tool C compress valve spring 3 and remove valve colle...

Page 300: ...seals are colored accord ing to their locations q Exhaust valve Black valve seal 7 1 q Air intake valve Blue valve seal 7 2 q Use tool Q to remove the valve seals 27 Front cover 1 Remove engine front...

Page 301: ...move front seal carrier assembly 7 2 Remove front seal 8 28 Supply pump drive gear Remove supply pump drive gear 1 29 Oil pump assembly Remove 4 bolts 1 and oil pump assembly 2 30 Oil pan 1 Remove 32...

Page 302: ...the mark of crankshaft gear 2 1 Remove bolts 3 and thrust plate 4 2 While turning the camshaft gear assembly 1 remove the camshaft 32 Tappet q Turn over the engine Remove 12 tappets 1 33 Piston cooli...

Page 303: ...plastic hammer and remove connecting rod cap 1 and con necting rod bearing as a unit 6 Push in and remove the piston and con necting rod assembly with a wood bar etc from the oil pan side while suppor...

Page 304: ...sing tool D remove piston ring 7 a Keep the piston connecting rod bearing piston rings and piston pin by the cylinders 35 Flywheel 1 Install lock plate 1 and remove mounting bolt 1 2 Install eyebolts...

Page 305: ...bolts 2 of main cap 1 2 Mark the position No on main cap 1 a Check that the embossed letters of BACK on side A of the main cap are directed toward the rear of the cylinder block 3 Insert bolts 2 in t...

Page 306: ...g 6 and 6 upper bearings 7 a Make the position marks on the main caps upper bearings and upper thrust bearings in the claws of the bearings and then keep them by the main caps so that they will not be...

Page 307: ...of tool R clockwise to pull up cylinder liner 1 from cylinder block 2 and then remove cylinder liner 1 with both hands a Mark the position No on the removed cylinder liner 41 Cylinder block 1 Remove c...

Page 309: ...114E 3 Series 1 SEN00464 01 ENGINE 1SHOP MANUAL 114E 3 Series 50 Disassembly and assembly1 Disassembly and assembly Part 2 Disassembly and assembly 2 General assembly of engine 2...

Page 310: ...ll deposits and broken pieces from sealing faces A B and C and polish those faces until the machined sur faces appear Take care not to scrub too much q Apply clean engine oil EO15W 40 to faces A and B...

Page 311: ...tion of the cylinder liner with tool L a Measure the projection at 4 places equally spaced on the periphery a Projection of liner 0 026 0 122 mm 7 If the projection of the cylinder liner varies more t...

Page 312: ...heck that their back sides are free from for eign matter a Apply engine oil EO15W 40 to the inside of the bearings Do not apply it to the back side however a When reusing the bearings check the marks...

Page 313: ...the rear of the cylinder block q Push in each main cap by hitting it lightly with a plastic hammer or rubber hammer 7 Tighten main cap mounting bolts 2 a Apply engine oil EO15W 40 to the bolts a Tight...

Page 314: ...the con necting rod and set in position 2 Using tool D fit piston rings 7 to the pis ton 3 Fitting oil ring Fit oil ring 9 so that its abutment joint will be at 180 from the end of expander 8 4 Fit se...

Page 315: ...bear ing is free from foreign matter q Set projection E of the bearing to cuts F of the connecting rod and cap 9 Set the crankshaft to the bottom dead center of the cylinder to install the piston and...

Page 316: ...kgm 4 60 5 Use angle tightening tool J q When not using tool J Make marks on the connecting rod cap and bolt with paint and then tighten the bolt by 60 5 12 After installing the piston and connecting...

Page 317: ...in the numeri cal order shown below 1 4 3 Mounting bolt 1st time 5 1 Nm 0 5 0 1 kgm 2nd time 24 4 Nm 2 4 0 4 kgm 3 Measuring backlash Rotate the crankshaft by 1 turn and mea sure backlash C between th...

Page 318: ...tool L a The end play depends on the thick ness of the thrust plate and the groove of the camshaft q End play Max 0 5 mm 5 Measure the backlash of camshaft gear assembly 1 with tool L q Backlash 0 2 0...

Page 319: ...contained in the spare front oil seal 2 Insert oil seal 8 from the front cover mounting side of carrier 7 q Set the seal flush with the face on the inserting side of the carrier 3 Install carrier asse...

Page 320: ...lts 6 2 Cover mounting face Gasket sealant LG 7 2 Tightening order of bolts Tighten the bolts in the numerical order shown below 1 26 3 Mounting bolt 3 Remove pilot tool 1 from the front oil seal 4 In...

Page 321: ...ot tool 15 Seal housing 1 Install seal housing 1 and gasket 3 to guide pin 3 2 Insert seal housing 1 aligning it with crankshaft 4 a Check that the end corner and lip slid ing surface of the crankshaf...

Page 322: ...5 2 Bed plate Mating surface with cyl inder block Gasket sealant LG 7 q Application drawing of gasket sealant Diameter of gasket sealant string Apply strings of gasket sealant 1 mm in diameter to the...

Page 323: ...oil pan 3 Oil pan Liquid gasket LG 7 a Apply gasket sealant strings simi larly to step 2 6 Install oil pan 2 with mounting bolts 1 7 Tightening order of bolts Tighten the bolts in the numerical order...

Page 324: ...ndicated lowest and highest values a After the crankshaft is rotated by 1 turn check that the dial gauge indi cates the value at the start of rotation q Measuring facial runout 1 Similarly to measurem...

Page 325: ...rence between the indicated lowest and highest values a After the flywheel is rotated by 1 turn check that the dial gauge indicates the value at the start of rotation q Measuring facial runout 1 Simil...

Page 326: ...ly engine oil EO15W 40 to the oil fil ter seal 2 Supply clean engine oil EO15W 40 into the oil filter 3 Install oil filter 1 3 Oil filter 13 2 Nm 1 3 0 2 kgm q You may tighten the oil filter 3 4 turns...

Page 327: ...lve collet is fitted to the groove of the valve stem 2 Before tightening the cylinder head mounting bolts check the following 1 Measure stem length a of each mounting bolt and check that it is shorter...

Page 328: ...at of each bolt 3 Tighten the bolts in the numerical order shown below 1 150 9 8 Nm 15 3 1 0 kgm 2 Return all bolts 360 3 115 4 9 Nm 11 7 0 5 kgm 4 Check tightening torque of 115 4 9 Nm 11 7 0 5 kgm 5...

Page 329: ...onnector d If the sealing surface of the outlet side is worn in contact unevenly or has a trace of leakage do not use the inlet connector If high pressure fuel leaks the seat surface is eroded and has...

Page 330: ...ci fied torque 3 Retainer 10 41 4 Nm 4 1 0 4 kgm Apply the caulking compound e hatched section to retainer 10 and the cylinder head 2 Caulking compound GE TOSHIBA SILICON TOSSEAL 381 25 Rocker arm ass...

Page 331: ...t drawing 3 Insert clearance gauge K between rocker arm 2 and crosshead 3 and set adjust ment screw 4 to a degree that you can move the clearance gauge lightly 4 Tighten locknut 5 under this condition...

Page 332: ...ounting nut 1 25 0 25 Nm 0 10 0 03 kgm a Locations of wiring harnesses a Install the injector wiring harness ter minal 5 in a direction where it will not interfere with the rocker arm 6 which moves up...

Page 333: ...he supply pump gear to the top and set the No 1 cylinder to the compression top dead center T D C 2 Fit the O ring and push in supply pump drive shaft 7 in supply pump drive gear 2 setting the pin of...

Page 334: ...l main controller assembly 1 to the cylin der block with mounting bolts 2 32 Fuel drain tube 1 Install tube 1 between the supply pump and drain and tube 2 between the cylin der head and drain 3 Joint...

Page 335: ...arness in reverse 6 Start the engine and check that fuel does not leak For the testing procedure see Testing and adjusting Testing fuel system for leakage 2 Replace relief valve 3 if necessary accordi...

Page 336: ...temporarily with mounting bolts 17 Tighten the bolts by hand 2 Tighten drain tube 18 temporarily 3 Install tube 7 between the supply pump and common rail 3 Nut 37 3 4 Nm 3 8 0 4 kgm 4 Install stay 15...

Page 337: ...Exhaust manifold and turbocharger 1 Fit the gaskets and install exhaust mani folds 4 and 5 Tighten the mounting bolts in the numerical order shown below 1 o 12 3 Tightening order of bolts 1 Tighten al...

Page 338: ...6 0 5 kgm 3 Drain hose clamping bolt 24 4 Nm 2 4 0 4 kgm 39 Thermostat Fit the O ring and install thermostat 1 40 Coolant connector 1 Install coolant outlet connector 1 2 Fit the gasket and install co...

Page 339: ...width across flats T 12 7 mm of the tensioner assembly 2 and rotate it to the opposite to the winding up direction to decrease the fan belt 1 tension k Make sure that the wrench is secured at the por...

Page 340: ...ove tool B 3 Place and fix engine assembly 1 on sta ble engine stand 1 4 Install plates 3 and 5 5 Install ground wire 4 of the main control ler to plate 3 47 Muffler 1 Install plate 1 2 Install plate...

Page 341: ...50 Disassembly and assembly SEN00464 01 114E 3 Series 33...

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