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40 Troubleshooting

SEN00458-01

114E-3 Series

S-8 Oil consumption is excessive (or exhaust smoke is blue)

General causes why oil consumption is excessive

Abnormal consumption of oil

Long-time operation of engine at low idle or high idle
(Do not run engine at idle for more than 20 minutes
continuously)

External leakage of oil

Wear of pats in lubrication system

Causes

Dust

suck

ed in from

int

ake

system

orn, d

amage

d va

lve

(stem, g

uid

e, sea

urbo

charge

Clo

gged

ather

, bre

ather

hose

Broken pi

ston

rin

orn piston ring

, cylin

der line

orn, d

amage

d re

ar o

seal

Broken oi

l co

oler

l leaka

ge fro

l co

oler

l leaka

ge fro

l fil

l leaka

ge fro

l p

ipi

l leaka

ge fro

l d

rain pl

l leaka

ge fro

l p

an,

cyl

inde

ad, etc.

orn seal at tu

ocharg

orn seal at blow

esti

ons

Confirm recent repair history
Degree of use of machine Operated for long period

E E E

Oil consumption suddenly increased

Oil must be added more frequently

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 intake system

Che

ck items

Inside of turbocharger intake outlet pipe is dirty with oil

Inside of turbocharger exhaust outlet pipe is dirty with oil

Q w

There is oil in coolant

Oil level in clutch chamber or damper chamber is high

Exhaust smoke is blue under light load

w w

Amount of blow-by gas

Excessive

w w

None

uble

shootin

When intake manifold is removed, dust is found inside

When intake manifold is removed, inside is found to be dirty abnormally

Excessive play of turbocharger shaft

q q

Inspect breather and breather hose directly

When compression pressure is measured, it is found to be low

q q

Inspect rear oil seal directly

Pressure-tightness test of oil cooler shows there is leakage

q q

There is external leakage of oil from engine

q q q q

Remedy

Correct

Repl

ace

Repl

ace

Repl

ace

Clea

Repl

ace

Repl

ace

Repl

ace

Repl

ace

Repl

ace

Correct

Содержание 114E-3 Series

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

Страница 2: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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