Komatsu 114 Series Diesel Engine Shop Manual SEBM024608 – PDF DOWNLOAD

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Komatsu 114 Series Diesel Engine Shop Manual SEBM024608 – PDF DOWNLOAD

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Komatsu 114 Series Diesel Engine Shop Manual SEBM024608 – PDF DOWNLOAD

Language : English
Pages : 444
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu 114 Series Diesel Engine Shop Manual SEBM024608 – PDF DOWNLOAD

COVER ........................................................................................  1
CONTENTS......................................................................................  2
LIST OF REVISED PAGES.........................................................................  3
01 GENERAL ................................................................................... 31
	APPLICABLE MACHINE........................................................................ 32
	SPECIFICATION............................................................................. 34
	OVERALL DRAWING........................................................................... 36
	WEIGHT TABLE.............................................................................. 41
	ENGINE PERFORMANCE CURVE.................................................................. 42
11 STRACTURE AND FUNCTION
.................................................................... 49
	AIR INTAKE DEVICE......................................................................... 50
	EXHAUST MANIFOLD.......................................................................... 53
	AIR CLEANER............................................................................... 54
	TURBOCHARGER.............................................................................. 55
	AFTERCOOLER............................................................................... 60
	CYLINDER HEAD............................................................................. 62
	CYLINDER BLOCK............................................................................ 66
	CYLINDER LINER............................................................................ 70
	MAIN CIRCULATION PART..................................................................... 72
	CRANK SHAFT............................................................................... 76
	PISTON・PISTON RING・PISTON PIN............................................................. 78
	CONNECTING ROD............................................................................ 80
	VIBRATION DAMPER.......................................................................... 82
	TIMING GEAR PORTION....................................................................... 84
	FRONT GEAR COVER.......................................................................... 85
	CAMSHAFT TIMING PIN....................................................................... 86
	TIMING GEAR............................................................................... 87
	CAM SHAFT................................................................................. 88
	VALVE MECHANISM........................................................................... 90
	VALVE, VALVE GUIDE........................................................................ 94
	ROCKER-ARM SHAFT・PUSH ROD・TAPPET.......................................................... 96
	OIL PAN................................................................................... 98
	FLYWHEEL, FLYWHEEL HOUSING................................................................100
	LUBRICATION SYSTEM DIAGRAM................................................................104
	OIL PUMP..................................................................................105
	OIL FILTER, OIL COOLER....................................................................108
	REGULATOR VALVE, SAFETY VALVE.............................................................109
	FUEL SYSTEM DIAGRAM.......................................................................110
	FUEL INJECTION PUMP.......................................................................112
	TIMING LOCK PIN OF FUEL INJECTION PUMP....................................................116
	FUEL FILTER...............................................................................117
	FUEL INJECTION NOZZLE.....................................................................118
	FUEL CUT SOLENOID.........................................................................120
	COOLING SYSTEM DIAGRAM....................................................................121
	WATER PUMP DRIVE..........................................................................122
	WATER PUMP (WITH ONE-PIECE BEARING, SHAFT, ONE-PIECE WATER SEAL)..........................124
	THERMOSTAT................................................................................125
	FAN DRIVE.................................................................................128
	ALTERNATOR................................................................................130
	STARTING MOTOR............................................................................133
	STARTING AID..............................................................................135
12 TESTING AND ADJUSTING
.....................................................................137
	SPECIAL TOOL LIST.........................................................................140
		SPECIAL TOOLS FOR INTAKE AND EXHAUST SYSTEM...........................................140
		SPECIAL TOOLS FOR CYLINDER HEAD SYSTEM................................................141
		SPECIAL TOOLS FOR ENGINE..............................................................145
		SPECIAL TOOLS FOR FUEL SYSTEM.........................................................149
		SPECIAL TOOLS FOR ACCESSORY COMPONENT SYSTEM..........................................150
		SPECIAL TOOLS FOR ELECTRICAL COMPONENT................................................151
		SPECIAL TOOLS FOR ENGINE PERFORMANCE TEST.............................................152
	TROUBLESHOOTING DEFECTIVE ACTUATION OF INTAKE AND EXHAUST SYSTEM..........................154
	MEASURING PLAY OF TURBOCHARGER ROTOR IN AXIAL AND RADIAL DIRECTION........................159
	TESTING TURBOCHARGER WESTGATE VALVE.......................................................160
	TESTING TURBOCHARGER WESTGATE CAPSULE.....................................................161
	TESTING ACTUATION OF TURBOCHARGER WESTGATE................................................161
	REPLACING TURBOCHARGER WESTGATE ACTUATOR BOOST CAPSULE....................................162
	ADJUSTING TURBOCHARGER WESTGATE ACTUATOR..................................................164
	MEASURING EXHAUST RESISTANCE..............................................................165
	REPLACING TURBOCHARGER....................................................................165
	TROUBLESHOOTING DEFECTIVE ACTUATION OF ENGINE.............................................166
		VALVE MECHANISM AND CYLINDER HEAD.....................................................166
		TESTING AIR SYSTEM AND FUEL SYSTEM....................................................166
		TESTING VALVE CLEARANCE...............................................................167
		TESTING COMPRESSION...................................................................167
		PISTON RING SEALING PERFORMANCE.......................................................167
		VALVE SEALING PERFORMANCE.............................................................168
		HEAD GASKET SEALIN PERFORMANCE........................................................168
		VALVE SEAL WEAR.......................................................................169
		PROTRUDING PORTION OF FUEL INJECTION NOZZLE...........................................170
		FRONT GEAR HOUSING AND GEAR TRAIN.....................................................171
		ROCKER LEVER, VALVE STEM, PUSH ROD, TAPPET, AND CAMSHAFT..............................172
		PISTON AND CONNECTING ROD.............................................................173
		CRANKSHAFT AND MAIN BEARING...........................................................175
		CYLINDER BLOCK........................................................................176
		FLYWHEEL HOUSING AND FLYWHEEL.........................................................177
	ADJUSTING VALVE CLEARANCE.................................................................178
		ADJUSTING 6-CYLINDER ENGINE...........................................................179
	TROUBLESHOOTING DEFECTIVE ACTUATION OF LUBRICATING SYSTEM.................................181
		HIGH PRESSURE.........................................................................181
		REGULATOR VALVE.......................................................................181
		LOW PRESSURE..........................................................................182
		OIL LEVEL.............................................................................182
		OIL FILTER............................................................................182
		OIL PRESSURE GAUGE....................................................................183
		OIL PAN SUCTION TUBE..................................................................183
		BEARING AND OIL PUMP..................................................................183
		DILUTION OF OIL.......................................................................183
		COOLING WATER IN OIL..................................................................184
		FUEL IN OIL ..........................................................................185
	FUEL INJECTION PUMP CALIBRATION DATA......................................................188
	RUNNING IN STANDARD.......................................................................193
	PERFORMANCE TEST CRITERIA.................................................................196
	TESTING FUEL FEED PUMP....................................................................198
		DISASSEMBLY AND ASSEMBLY OF FUEL FEED PUMP............................................199
	ADJUSTING FUEL CUT-OFF SOLENOID...........................................................201
		DIRECTION OF FUEL CUT-OFF SOLENOID....................................................201
		ADJUSTING FUEL CUT-OFF SOLENOID.......................................................202
		INSTALLATION OF MECHANICALLY OPERATED SOLENOID, CYLINDER BLOCK........................203
	TESTING FOR AIR INSIDE THE FUEL SYSTEM....................................................204
	TESTING WATER SEPARATOR, FUEL FILTER......................................................206
	TESTING HIGH-PRESSURE FUEL PIPING.........................................................207
	TESTING FUEL INJECTION NOZZLE.............................................................208
	TESTING FUEL DRAIN PIPING.................................................................210
	BLEEDING AIR FROM FUEL SYSTEM.............................................................210
		BLEEDING AIR FROM LOW-PRESSURE CIRCUIT AND FUEL FILTER................................211
		BLEEDING AIR FROM FUEL INJECTION PUMP.................................................211
		BLEEDING AIR FROM HIGH-PRESSURE CIRCUIT...............................................212
	ADJUSTING TIMING OF FUEL INJECTION PUMP...................................................213
	TROUBLESHOOTING DEFECTIVE OPERATION OF COOLING SYSTEM.....................................216
		TROUBLESHOOTING.......................................................................216
		RADIATOR CAP..........................................................................218
		WATER PUMP............................................................................219
		RADIATOR, FAN, AND RADIATOR SHUTTER...................................................220
		THERMOSTAT............................................................................221
		WATER TEMPERATURE GAUGE, EXCESSIVE FUEL, OVERLOAD.....................................223
	STANDARD VALUE TABLE FOR TESTING, ADJUSTING, AND TROUBLESHOOTING..........................224
	TROUBLESHOOTING OF ENGINE (S MODE)........................................................227
		METHOD OF USING TROUBLESHOOTING CHARTS................................................228
		S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME).........................232
		S-2 ENGINE DOES NOT START.............................................................233
			(1) ENGINE DOES NOT TURN..........................................................233
			(2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED)......234
			(3) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)....235
		S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)..............................236
		S-4 ENGINE STOPS DURING OPERATIONS....................................................237
		S-5 ENGING DOES NOT ROTATE SMOOTHLY (HUNTING).........................................238
		S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)..............................................239
		S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)....................................240
		S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)...........................241
		S-9 OIL BECOMES CONTAMINATED QUICKLY..................................................242
		S-10 FUEL CONSUMPTION IS EXCESSIVE....................................................243
		S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN..........244
		S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE).......................245
		S-13 OIL LEVEL RISES (WATER, FUEL IN OIL).............................................246
		S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING).................................247
		S-15 ABNORMAL NOISE IS MADE...........................................................248
		S-16 VIBRATION IS EXCESSIVE...........................................................249
13 DISASSEMBLY AND ASSEMBLY
..................................................................251
	SPECIAL TOOL LIST.........................................................................254
		SPECIAL TOOLS FOR DISASSEMBLY AND ASSEMBLY............................................254
	OUTLINE OF DISASSEMBLY AND ASSEMBLY OF ENGINE.............................................258
		OUTLINE...............................................................................258
	OVERALL DISASSEMBLY OF ENGINE.............................................................259
		ENGINE LIFTING TOOL AND BRACKET.......................................................259
		PREPARATION FOR STEAM CLEANING OF ENGINE..............................................259
		STEAM CLEANING OF ENGINE..............................................................259
		DRAINING OIL..........................................................................260
		DRAINING COOLANT......................................................................260
		REMOVAL OF OIL FILTER.................................................................260
		REMOVAL OF FUEL FILTER................................................................261
		REMOVAL OF FUEL SUPPLY PIPE (LOW-PRESSURE SIDE).......................................261
		REMOVAL OF FUEL FEED PUMP.............................................................261
		REMOVAL OF FUEL SUPPLY PIPE (HIGH-PRESSURE SIDE)......................................262
		REMOVAL OF FUEL INJECTION PUMP FUEL SUPPLY PIPES......................................262
		REMOVAL OF BOOST COMPENSATOR TUBE.....................................................262
		REMOVAL OF TACHOMETER DRIVE...........................................................263
		REMOVAL OF FUEL INJECTION PUMP........................................................263
		REMOVAL OF AIR CONDITIONER COMPRESSOR.................................................264
		INSTALLATION OF ENGINE TO ENGINE STAND................................................265
		REMOVAL OF TURBOCHARGER EXHAUST OUTLET CONNECTOR......................................266
		REMOVAL OF WESTGATE ACTUATOR HOSE.....................................................266
		REMOVAL OF CYLINDER BLOCK BREATHER TUBE...............................................266
		REMOVAL OF CROSSOVER TUBE.............................................................267
		REMOVAL OF INTAKE MANIFOLD COVER......................................................267
		REMOVAL OF AFTERCOOLER................................................................267
		REMOVAL OF FUEL DRAIN MANIFOLD........................................................268
		REMOVAL OF INJECTOR...................................................................268
		REMOVAL OF CYLINDER HEAD COVER........................................................269
		REMOVAL OF ROCKER LEVER...............................................................269
		REMOVAL OF PUSH ROD...................................................................270
		REMOVAL OF TURBOCHARGER OIL SUPPLY HOSE...............................................270
		REMOVAL OF TURBOCHARGER OIL DRAIN TUBE................................................270
		REMOVAL OF TURBOCHARGER...............................................................270
		REMOVAL OF EXHAUST MANIFOLD...........................................................271
		REMOVAL OF DRIVE BELT.................................................................271
		REMOVAL OF BELT TENSIONER.............................................................271
		REMOVAL OF BELT TENSIONER BRACKET.....................................................271
		REMOVAL OF ALTERNATOR BRACKET.........................................................272
		REMOVAL OF ALTERNATOR.................................................................272
		REMOVAL OF ALTERNATOR BRACKET.........................................................272
		REMOVAL OF COOLANT OUTLET CONNECTOR...................................................272
		REMOVAL OF COOLANT AIR BLEED TUBE.....................................................273
		REMOVAL OF COOLANT AIR BLEED VALVE....................................................273
		REMOVAL OF THERMOSTAT AND HOUSING.....................................................273
		REMOVAL OF THERMOSTAT AND HOUSING.....................................................273
		REMOVAL OF CYLINDER HEAD..............................................................274
		DRAINING OIL FROM OIL COOLER..........................................................274
		REMOVAL OF COOLANT INLET CONNECTOR....................................................274
		REMOVAL OF FAN HUB ASSEMBLY...........................................................275
		REMOVAL OF WATER PUMP.................................................................275
		REMOVAL OF VIBRATION DAMPER...........................................................276
		REMOVAL OF GEAR COVER.................................................................276
		REMOVAL OF FRONT CRANKSHAFT SEAL......................................................276
		REMOVAL OF STARTING MOTOR.............................................................276
		REMOVAL OF COOLANT HEATER.............................................................277
		REMOVAL OF FLYWHEEL...................................................................277
		REMOVAL OF FLYWHEEL HOUSING...........................................................277
		REMOVAL OF OIL PAN....................................................................277
		REMOVAL OF SUCTION TUBE...............................................................278
		REMOVAL OF REAR CRANKSHAFT SEAL.......................................................278
		REMOVAL OF CAMSHAFT...................................................................278
		REMOVAL OF VALVE TAPPET...............................................................280
		MEASUREMENT OF OIL PUMP GEAR BACKLASH.................................................280
		REMOVAL OF OIL PUMP...................................................................281
		REMOVAL OF ENGINE FRONT SUPPORT.......................................................281
		REMOVAL OF GEAR HOUSING...............................................................281
		REMOVAL OF CARBON ACCUMULATED ON CYLINDER LINER.......................................282
		REMOVAL OF PISTON ASSEMBLY............................................................283
		REMOVAL OF PISTON PIN.................................................................284
		REMOVAL OF PISTON RING................................................................284
		REMOVAL OF MAIN BEARING CAP...........................................................285
		REMOVAL OF MAIN BEARING (LOWER).......................................................285
		REMOVAL OF CRANKSHAFT.................................................................286
		REMOVAL OF MAIN BEARING (UPPER).......................................................286
		REMOVAL OF PISTON COOLING NOZZLE......................................................286
		TESTING PROTRUSION OF CYLINDER LINER..................................................286
		REMOVAL OF CYLINDER LINER.............................................................287
		REPLACEMENT OF EXPANSION PLUG.........................................................288
		REMOVAL OF EXPANSION PLUG.............................................................288
		REMOVAL OF CYLINDER BLOCK FROM ENGINE STAND...........................................289
	ASSEMBLY OF ENGINE........................................................................290
		INSTALL THE CYLINDER BLOCK TO THE ROLL-OVER STAND.....................................290
		INSTALLATION OF CYLINDER LINER........................................................290
		INSTALLATION OF TAPPET................................................................295
		INSTALLATION OF PISTON COOLING NOZZLE.................................................295
		INSTALLATION OF MAIN BEARING (UPPER)..................................................296
		INSTALLATION OF CRANKSHAFT............................................................298
		INSTALLATION OF MAIN BEARING (LOWER)..................................................299
		INSTALLATION OF MAIN BEARING CAP......................................................299
		INSTALLATION OF CONNECTING ROD BOLT...................................................302
		INSTALLATION OF PISTON PIN............................................................303
		MEASURING PISTON RING END GAP.........................................................303
		INSTALLATION OF PISTON RING...........................................................304
		INSTALLATION OF PISTON ASSEMBLY.......................................................306
		INSTALLATION OH GEAR HOUSING..........................................................311
		INSTALLATION OF OIL PUMP..............................................................312
		INSTALLATION OF CAMSHAFT..............................................................314
		INSTALLATION OF WATER PUMP............................................................316
		INSTALLATION OF OIL SUCTION TUBE......................................................316
		INSTALLATION OF REAR CRANKSHAFT SEAL..................................................316
		INSTALLATION OF WEAR SLEEVE, REAR CRANKSHAFT SEAL.....................................317
		INSTALLATION OF OIL PAN...............................................................320
		INSTALLATION OF TIMING PIN ASSEMBLY...................................................321
		INSTALLATION OF FLYWHEEL HOUSING......................................................324
		TESTING COAXIALITY OF FLYWHEEL HOUSING BORE...........................................325
		INSTALLATION OF FLYWHEEL..............................................................329
		MEASURING RUNOUT OF FLYWHEEL BORE.....................................................331
		MEASURING FACE RUNOUT OF FLYWHEEL.....................................................333
		INSTALLATION OF STARTING MOTOR........................................................334
		INSTALLATION OF OIL COOLER............................................................334
		INSTALLATION OF OIL FILTER............................................................335
		INSTALLATION OF CYLINDER HEAD.........................................................335
		INSTALLATION OF PUSH ROD..............................................................339
		ASSEMBLY OF ROCKER LEVER AND SHAFT....................................................339
		INSTALLATION OF ROCKER LEVER ASSEMBLY.................................................341
		ADJUSTING VALVE CLEARANCE.............................................................342
		INSTALLATION OF HEAD COVER............................................................344
		INSTALLATION OF CYLINDER BLOCK BREATHER TUBE..........................................345
		INSTALLATION OF INJECTOR..............................................................345
		INSTALLATION OF FUEL DRAIN MANIFOLD...................................................346
		INSTALLATION OF ENGINE LIFTING BRACKET................................................346
		INSTALLATION OF INTAKE MANIFOLD COVER.................................................346
		INSTALLATION OF AFTERCOOLER...........................................................347
		INSTALLATION OF EXHAUST MANIFOLD......................................................347
		INSTALLATION OF TURBOCHARGER..........................................................348
		INSTALLATION OF TURBOCHARGER OIL DRAIN TUBE...........................................349
		INSTALLATION OF TURBOCHARGER OIL SUPPLY HOSE..........................................351
		INSTALLATION OF TURBOCHARGER EXHAUST OUTLET PORT CONNECTOR............................351
		INSTALLATION OF CROSSOVER.............................................................351
		INSTALLATION OF THERMOSTAT AND HOUSING................................................351
		INSTALLATION OF COOLANT OUTLET CONNECTOR..............................................352
		INSTALLATION OF COOLANT AIR BLEED JOINT...............................................352
		INSTALLATION OF COOLANT AIR BLEED VALVE...............................................352
		INSTALLATION OF COOLANT AIR BLEED TUBE................................................353
		INSTALLATION OF COOLANT INLET CONNECTOR...............................................353
		INSTALLATION OF ALTERNATOR BRACKET....................................................353
		INSTALLATION OF ALTERNATOR............................................................353
		INSTALLATION OF ALTERNATOR BRACE......................................................354
		INSTALLATION OF BELT TENSIONER BRACKET................................................355
		INSTALLATION OF BELT TENSIONER........................................................355
		REMOVAL FROM ENGINE ASSEMBLY STAND....................................................355
		INSTALLATION OF FAN HUB ASSEMBLY......................................................356
		INSTALLATION OF FUEL INJECTION PUMP...................................................356
		INSTALLATION OF FUEL INJECTION PUMP, FUEL SUPPLY LINE.................................361
		INSTALLATION OF FUEL FILTER HEAD......................................................361
		INSTALLATION OF FUEL FILTER...........................................................362
		INSTALLATION OF FUEL INJECTION PIPE (HIGH-PRESSURE SIDE)..............................362
		INSTALLATION OF BOOST COMPENSATOR TUBE................................................363
		INSTALLATION OF FRONT CRANKSHAFT SEAL.................................................363
		INSTALLATION OF FRONT CRANKSHAFT WEAR SLEEVE..........................................363
		INSTALLATION OF GEAR COVER............................................................366
		INSTALLATION OF TACHOMETER DRIVE......................................................367
		INSTALLATION OF CRANKSHAFT PULLEY, VIBRATION DAMPER...................................367
		INSTALLATION OF BELT..................................................................368
		INSTALLATION OF ENGINE FRONT SUPPORT..................................................368
		INSTALLATION OF FUEL FEED PUMP........................................................368
		INSTALLATION OF FUEL PIPING TUBE (LOW-PRESSURE SIDE)..................................369
		INSTALLATION OF FUEL PUMP SOLENOID....................................................369
		INSTALLATION OF AIR COMPRESSOR........................................................369
		INSTALLATION OF ENGINE ACCESSORY......................................................371
15 REPAIR AND REPLACEMENT OF PARTS
...........................................................373
	OUTLINE...................................................................................374
		REPAIR GUIDE LINE.....................................................................374
		WHEN SHOULD SUBSTITUTE REPAIRS BE CARRIED OUT.........................................374
		INSPECTION............................................................................374
		TO ENSURE SAFETY, FOLLOW ALL INSTRUCTIONS IN MANUAL...................................374
		FOLLOW WASHING METHODS GIVEN IN MANUAL................................................374
		FOLLOW INSPECTION METHODS GIVEN IN MANUAL.............................................374
	REPAIR METHODS FOR SCREWS USING COIL THREAD INSERT........................................375
	METHOD FOR USING TAPER THREAD PLUGS TO SEAL POCKETS AND SMALL HOLES IN CASTINGS...........376
		REPAIR PROCEDURE......................................................................376
	METHOD FOR REPAIRING TAPER THREAD PLUG HOLES WORN BY LARGE SIZE COPPER PLATED PLUGS.......379
	METHOD OF USING FILLER METAL IN EMERGENCY REPAIRS.........................................380
	INSPECTION FOR REUSE OF CYLINDER BLOCK....................................................381
	INSTALLATION OF EXPANSION PLUGS...........................................................385
		INSTALLATION OF PIPE PLUGS............................................................385
	INSTALLATION OF EXPANSION PLUG TO CAMSHAFT HOLE...........................................388
	REMOVAL OF CAMSHAFT BUSHING...............................................................389
		CLEANING OF CAMSHAFT BUSHING HOLE.....................................................389
	INSTALLATION OF CAMSHAFT BUSHING..........................................................390
	CLEANING AND INSPECTION OF CYLINDER LINERS BEFORE REUSING THEM............................393
		CREANING OF CYLINDER LINERS...........................................................393
		INSPECTION OF CYLINDER LINERS.........................................................394
	CLEANING AND INSPECTION OF PISTON BEFORE REUSING IT.......................................396
		REMOVE THE PISTON RINGS...............................................................396
		CLEANING OF PISTONS...................................................................396
		INSPECTION OF PISTONS.................................................................397
	CLEANING AND INSPECTION OF CRANKSHAFT BEFORE REUSING IT...................................399
		CLEANING OF CRANKSHAFT................................................................399
		INSPECTION OF CRANKSHAFT..............................................................399
	REPLACEMENT OF CRANKSHAFT GEAR............................................................403
		REMOVAL OF CRANKSHAFT GEAR............................................................403
		INSPECTION OF CRANKSHAFT..............................................................403
		INSTALLATION OF CRANKSHAFT GEAR.......................................................404
	CLEANING AND INSPECTION OF MAIN BEARINGS BEFORE REUSING THEM..............................406
		GENERAL INFORMATION...................................................................406
		CLEANING OF MAIN BEARINGS.............................................................406
		INSPECTION OF MAIN BEARINGS...........................................................406
		INSPECTION OF THRUST BEARING..........................................................407
	CLEANING AND INSPECTION OF MAIN BEARING CAPS AND MOUNTING BOLTS BEFORE REUSING THEM.......408
		CLEANING..............................................................................408
		INSPECTION............................................................................408
	CLEANING AND INSPECTION OF CONNECTING ROD BEARINGS BEFORE REUSING THEM....................409
		CLEANING OF CONNECTING ROD BEARINGS...................................................409
		INSPECTION OF CONNECTING ROD BEARINGS.................................................409
	CLEANING AND INSPECTION OF CONNECTING RODS BEFORE REUSING THEM............................411
		CLEANING OF CONNECTING RODS...........................................................411
		INSPECTION OF CONNECTIONG RODS........................................................411
	INSPECTION OF CONNECTING RODS FOR BEND AND TORSION........................................414
		CALIBRATION OF FIXING TOOL............................................................414
		INSPECTION OF ALIGNMENT OF CONNECTING RODS............................................415
		REPAIR PROCEDURE FOR CONNECTING RODS..................................................415
	REPLACEMENT OF CONNECTING ROD BUSHINGS....................................................416
		REMOVAL...............................................................................416
		INSTALLATION..........................................................................418
		INSPECTION............................................................................420
	REPLACEMENT OF VALVE INSERTS OF CYLINDER HEAD.............................................421
		REMOVAL...............................................................................421
		INSPECTION............................................................................423
		ASSEMBLY..............................................................................423
		INSPECTION OF VALVE GUIDES............................................................424
		INSPECTION OF VALVE SEAT INSERTS......................................................425
		INSPECTION OF VALVE SPRINGS...........................................................426
		INSPECTION OF VALVE STEM SEAL.........................................................427
		INSPECTION OF VALVES..................................................................427
		GRINDING OF VALVES....................................................................428
		GRINDING OF VALVE SEAT INSERTS........................................................429
		ASSEMBLY..............................................................................433
		INSTALLATION OF PIPE PLUGS............................................................433
	REPLACEMENT OF VALVE GUIDES OF CYLINDER HEAD..............................................436
		DISASSEMBLY...........................................................................436
		INSPECTION............................................................................436
		ASSEMBLY..............................................................................436
	CYLINDER HEAD-PRESSURE TEST...............................................................439
	VACUUM TEST ON VALVE SEATS OF CYLINDER HEAD...............................................441
	CLEANING AND INSPECTION OF CYLINDER HEAD BOLTS............................................443
		CLEANING..............................................................................443
		INSPECTION............................................................................443
		FREE LENGTH-MEASUREMENT...............................................................444

DESCRIPTION:

Komatsu 114 Series Diesel Engine Shop Manual SEBM024608 – PDF DOWNLOAD

GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.
STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards.
TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” with “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts. The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. In addition, this section may give the specifications of attachments and options together.

S.S 21/12/24