Komatsu 114 Series Diesel Engine Shop Manual SEBM024611 – PDF DOWNLOAD
FILE DETAILS:
Komatsu 114 Series Diesel Engine Shop Manual SEBM024611 – PDF DOWNLOAD
Language : English
Pages :446
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Komatsu 114 Series Diesel Engine Shop Manual SEBM024611 – PDF DOWNLOAD
FOREWORD
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.
TABLE OF CONTENTS:
Komatsu 114 Series Diesel Engine Shop Manual SEBM024611 – PDF DOWNLOAD
COVER 1
CONTENTS 2
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 HOUSING100
LUBRICATION SYSTEM DIAGRAM104
OIL PUMP105
OIL FILTER, OIL COOLER108
REGULATOR VALVE, SAFETY VALVE109
FUEL SYSTEM DIAGRAM110
FUEL INJECTION PUMP112
TIMING LOCK PIN OF FUEL INJECTION PUMP116
FUEL FILTER117
FUEL INJECTION NOZZLE118
FUEL CUT SOLENOID120
COOLING SYSTEM DIAGRAM121
WATER PUMP DRIVE122
WATER PUMP (WITH ONE-PIECE BEARING, SHAFT, ONE-PIECE WATER SEAL)124
THERMOSTAT125
FAN DRIVE128
ALTERNATOR130
STARTING MOTOR133
STARTING AID135
12 TESTING AND ADJUSTING 137
SPECIAL TOOL LIST140
SPECIAL TOOLS FOR INTAKE AND EXHAUST SYSTEM140
SPECIAL TOOLS FOR CYLINDER HEAD SYSTEM141
SPECIAL TOOLS FOR ENGINE145
SPECIAL TOOLS FOR FUEL SYSTEM149
SPECIAL TOOLS FOR ACCESSORY COMPONENT SYSTEM150
SPECIAL TOOLS FOR ELECTRICAL COMPONENT151
SPECIAL TOOLS FOR ENGINE PERFORMANCE TEST152
TROUBLESHOOTING DEFECTIVE ACTUATION OF INTAKE AND EXHAUST SYSTEM154
MEASURING PLAY OF TURBOCHARGER ROTOR IN AXIAL AND RADIAL DIRECTION159
TESTING TURBOCHARGER WESTGATE VALVE160
TESTING TURBOCHARGER WESTGATE CAPSULE161
TESTING ACTUATION OF TURBOCHARGER WESTGATE161
REPLACING TURBOCHARGER WESTGATE ACTUATOR BOOST CAPSULE162
ADJUSTING TURBOCHARGER WESTGATE ACTUATOR164
MEASURING EXHAUST RESISTANCE165
REPLACING TURBOCHARGER165
TROUBLESHOOTING DEFECTIVE ACTUATION OF ENGINE166
VALVE MECHANISM AND CYLINDER HEAD166
TESTING AIR SYSTEM AND FUEL SYSTEM166
TESTING VALVE CLEARANCE167
TESTING COMPRESSION167
PISTON RING SEALING PERFORMANCE167
VALVE SEALING PERFORMANCE168
HEAD GASKET SEALIN PERFORMANCE168
VALVE SEAL WEAR169
PROTRUDING PORTION OF FUEL INJECTION NOZZLE170
FRONT GEAR HOUSING AND GEAR TRAIN171
ROCKER LEVER, VALVE STEM, PUSH ROD, TAPPET, AND CAMSHAFT172
PISTON AND CONNECTING ROD173
CRANKSHAFT AND MAIN BEARING175
CYLINDER BLOCK176
FLYWHEEL HOUSING AND FLYWHEEL177
ADJUSTING VALVE CLEARANCE178
ADJUSTING 6-CYLINDER ENGINE179
TROUBLESHOOTING DEFECTIVE ACTUATION OF LUBRICATING SYSTEM181
HIGH PRESSURE181
REGULATOR VALVE181
LOW PRESSURE182
OIL LEVEL182
OIL FILTER182
OIL PRESSURE GAUGE183
OIL PAN SUCTION TUBE183
BEARING AND OIL PUMP183
DILUTION OF OIL183
COOLING WATER IN OIL184
FUEL IN OIL 185
FUEL INJECTION PUMP CALIBRATION DATA188
RUNNING IN STANDARD193
PERFORMANCE TEST CRITERIA196
TESTING FUEL FEED PUMP198
DISASSEMBLY AND ASSEMBLY OF FUEL FEED PUMP199
ADJUSTING FUEL CUT-OFF SOLENOID201
DIRECTION OF FUEL CUT-OFF SOLENOID201
ADJUSTING FUEL CUT-OFF SOLENOID202
INSTALLATION OF MECHANICALLY OPERATED SOLENOID, CYLINDER BLOCK203
TESTING FOR AIR INSIDE THE FUEL SYSTEM204
TESTING WATER SEPARATOR, FUEL FILTER206
TESTING HIGH-PRESSURE FUEL PIPING207
TESTING FUEL INJECTION NOZZLE208
TESTING FUEL DRAIN PIPING210
BLEEDING AIR FROM FUEL SYSTEM210
BLEEDING AIR FROM LOW-PRESSURE CIRCUIT AND FUEL FILTER211
BLEEDING AIR FROM FUEL INJECTION PUMP211
BLEEDING AIR FROM HIGH-PRESSURE CIRCUIT212
ADJUSTING TIMING OF FUEL INJECTION PUMP213
TROUBLESHOOTING DEFECTIVE OPERATION OF COOLING SYSTEM216
TROUBLESHOOTING216
RADIATOR CAP218
WATER PUMP219
RADIATOR, FAN, AND RADIATOR SHUTTER220
THERMOSTAT221
WATER TEMPERATURE GAUGE, EXCESSIVE FUEL, OVERLOAD223
STANDARD VALUE TABLE FOR TESTING, ADJUSTING, AND TROUBLESHOOTING224
TROUBLESHOOTING OF ENGINE (S MODE)227
METHOD OF USING TROUBLESHOOTING CHARTS228
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)232
S-2 ENGINE DOES NOT START233
(1) ENGINE DOES NOT TURN233
(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 OPERATIONS237
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 QUICKLY242
S-10 FUEL CONSUMPTION IS EXCESSIVE243
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN244
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 MADE248
S-16 VIBRATION IS EXCESSIVE249
13 DISASSEMBLY AND ASSEMBLY 251
SPECIAL TOOL LIST254
SPECIAL TOOLS FOR DISASSEMBLY AND ASSEMBLY254
OUTLINE OF DISASSEMBLY AND ASSEMBLY OF ENGINE258
OUTLINE258
OVERALL DISASSEMBLY OF ENGINE259
ENGINE LIFTING TOOL AND BRACKET259
PREPARATION FOR STEAM CLEANING OF ENGINE259
STEAM CLEANING OF ENGINE259
DRAINING OIL260
DRAINING COOLANT260
REMOVAL OF OIL FILTER260
REMOVAL OF FUEL FILTER261
REMOVAL OF FUEL SUPPLY PIPE (LOW-PRESSURE SIDE)261
REMOVAL OF FUEL FEED PUMP261
REMOVAL OF FUEL SUPPLY PIPE (HIGH-PRESSURE SIDE)262
REMOVAL OF FUEL INJECTION PUMP FUEL SUPPLY PIPES262
REMOVAL OF BOOST COMPENSATOR TUBE262
REMOVAL OF TACHOMETER DRIVE263
REMOVAL OF FUEL INJECTION PUMP263
REMOVAL OF AIR CONDITIONER COMPRESSOR264
INSTALLATION OF ENGINE TO ENGINE STAND265
REMOVAL OF TURBOCHARGER EXHAUST OUTLET CONNECTOR266
REMOVAL OF WESTGATE ACTUATOR HOSE266
REMOVAL OF CYLINDER BLOCK BREATHER TUBE266
REMOVAL OF CROSSOVER TUBE267
REMOVAL OF INTAKE MANIFOLD COVER267
REMOVAL OF AFTERCOOLER267
REMOVAL OF FUEL DRAIN MANIFOLD268
REMOVAL OF INJECTOR268
REMOVAL OF CYLINDER HEAD COVER269
REMOVAL OF ROCKER LEVER269
REMOVAL OF PUSH ROD270
REMOVAL OF TURBOCHARGER OIL SUPPLY HOSE270
REMOVAL OF TURBOCHARGER OIL DRAIN TUBE270
REMOVAL OF TURBOCHARGER270
REMOVAL OF EXHAUST MANIFOLD271
REMOVAL OF DRIVE BELT271
REMOVAL OF BELT TENSIONER271
REMOVAL OF BELT TENSIONER BRACKET271
REMOVAL OF ALTERNATOR BRACKET272
REMOVAL OF ALTERNATOR272
REMOVAL OF ALTERNATOR BRACKET272
REMOVAL OF COOLANT OUTLET CONNECTOR272
REMOVAL OF COOLANT AIR BLEED TUBE273
REMOVAL OF COOLANT AIR BLEED VALVE273
REMOVAL OF THERMOSTAT AND HOUSING273
REMOVAL OF THERMOSTAT AND HOUSING273
REMOVAL OF CYLINDER HEAD274
DRAINING OIL FROM OIL COOLER274
REMOVAL OF COOLANT INLET CONNECTOR274
REMOVAL OF FAN HUB ASSEMBLY275
REMOVAL OF WATER PUMP275
REMOVAL OF VIBRATION DAMPER276
REMOVAL OF GEAR COVER276
REMOVAL OF FRONT CRANKSHAFT SEAL276
REMOVAL OF STARTING MOTOR276
REMOVAL OF COOLANT HEATER277
REMOVAL OF FLYWHEEL277
REMOVAL OF FLYWHEEL HOUSING277
REMOVAL OF OIL PAN277
REMOVAL OF SUCTION TUBE278
REMOVAL OF REAR CRANKSHAFT SEAL278
REMOVAL OF CAMSHAFT278
REMOVAL OF VALVE TAPPET280
MEASUREMENT OF OIL PUMP GEAR BACKLASH280
REMOVAL OF OIL PUMP281
REMOVAL OF ENGINE FRONT SUPPORT281
REMOVAL OF GEAR HOUSING281
REMOVAL OF CARBON ACCUMULATED ON CYLINDER LINER282
REMOVAL OF PISTON ASSEMBLY283
REMOVAL OF PISTON PIN284
REMOVAL OF PISTON RING284
REMOVAL OF MAIN BEARING CAP285
REMOVAL OF MAIN BEARING (LOWER)285
REMOVAL OF CRANKSHAFT286
REMOVAL OF MAIN BEARING (UPPER)286
REMOVAL OF PISTON COOLING NOZZLE286
TESTING PROTRUSION OF CYLINDER LINER286
REMOVAL OF CYLINDER LINER287
REPLACEMENT OF EXPANSION PLUG288
REMOVAL OF EXPANSION PLUG288
REMOVAL OF CYLINDER BLOCK FROM ENGINE STAND289
ASSEMBLY OF ENGINE290
INSTALL THE CYLINDER BLOCK TO THE ROLL-OVER STAND290
INSTALLATION OF CYLINDER LINER290
INSTALLATION OF TAPPET295
INSTALLATION OF PISTON COOLING NOZZLE295
INSTALLATION OF MAIN BEARING (UPPER)296
INSTALLATION OF CRANKSHAFT298
INSTALLATION OF MAIN BEARING (LOWER)299
INSTALLATION OF MAIN BEARING CAP299
INSTALLATION OF CONNECTING ROD BOLT302
INSTALLATION OF PISTON PIN303
MEASURING PISTON RING END GAP303
INSTALLATION OF PISTON RING304
INSTALLATION OF PISTON ASSEMBLY306
INSTALLATION OH GEAR HOUSING311
INSTALLATION OF OIL PUMP312
INSTALLATION OF CAMSHAFT314
INSTALLATION OF WATER PUMP316
INSTALLATION OF OIL SUCTION TUBE316
INSTALLATION OF REAR CRANKSHAFT SEAL316
INSTALLATION OF WEAR SLEEVE, REAR CRANKSHAFT SEAL317
INSTALLATION OF OIL PAN320
INSTALLATION OF TIMING PIN ASSEMBLY321
INSTALLATION OF FLYWHEEL HOUSING324
TESTING COAXIALITY OF FLYWHEEL HOUSING BORE325
INSTALLATION OF FLYWHEEL329
MEASURING RUNOUT OF FLYWHEEL BORE331
MEASURING FACE RUNOUT OF FLYWHEEL333
INSTALLATION OF STARTING MOTOR334
INSTALLATION OF OIL COOLER334
INSTALLATION OF OIL FILTER335
INSTALLATION OF CYLINDER HEAD335
INSTALLATION OF PUSH ROD339
ASSEMBLY OF ROCKER LEVER AND SHAFT339
INSTALLATION OF ROCKER LEVER ASSEMBLY341
ADJUSTING VALVE CLEARANCE342
INSTALLATION OF HEAD COVER344
INSTALLATION OF CYLINDER BLOCK BREATHER TUBE345
INSTALLATION OF INJECTOR345
INSTALLATION OF FUEL DRAIN MANIFOLD346
INSTALLATION OF ENGINE LIFTING BRACKET346
INSTALLATION OF INTAKE MANIFOLD COVER346
INSTALLATION OF AFTERCOOLER347
INSTALLATION OF EXHAUST MANIFOLD347
INSTALLATION OF TURBOCHARGER348
INSTALLATION OF TURBOCHARGER OIL DRAIN TUBE349
INSTALLATION OF TURBOCHARGER OIL SUPPLY HOSE351
INSTALLATION OF TURBOCHARGER EXHAUST OUTLET PORT CONNECTOR351
INSTALLATION OF CROSSOVER351
INSTALLATION OF THERMOSTAT AND HOUSING351
INSTALLATION OF COOLANT OUTLET CONNECTOR352
INSTALLATION OF COOLANT AIR BLEED JOINT352
INSTALLATION OF COOLANT AIR BLEED VALVE352
INSTALLATION OF COOLANT AIR BLEED TUBE353
INSTALLATION OF COOLANT INLET CONNECTOR353
INSTALLATION OF ALTERNATOR BRACKET353
INSTALLATION OF ALTERNATOR353
INSTALLATION OF ALTERNATOR BRACE354
INSTALLATION OF BELT TENSIONER BRACKET355
INSTALLATION OF BELT TENSIONER355
REMOVAL FROM ENGINE ASSEMBLY STAND355
INSTALLATION OF FAN HUB ASSEMBLY356
INSTALLATION OF FUEL INJECTION PUMP356
INSTALLATION OF FUEL INJECTION PUMP, FUEL SUPPLY LINE361
INSTALLATION OF FUEL FILTER HEAD361
INSTALLATION OF FUEL FILTER362
INSTALLATION OF FUEL INJECTION PIPE (HIGH-PRESSURE SIDE)362
INSTALLATION OF BOOST COMPENSATOR TUBE363
INSTALLATION OF FRONT CRANKSHAFT SEAL363
INSTALLATION OF FRONT CRANKSHAFT WEAR SLEEVE363
INSTALLATION OF GEAR COVER366
INSTALLATION OF TACHOMETER DRIVE367
INSTALLATION OF CRANKSHAFT PULLEY, VIBRATION DAMPER367
INSTALLATION OF BELT368
INSTALLATION OF ENGINE FRONT SUPPORT368
INSTALLATION OF FUEL FEED PUMP368
INSTALLATION OF FUEL PIPING TUBE (LOW-PRESSURE SIDE)369
INSTALLATION OF FUEL PUMP SOLENOID369
INSTALLATION OF AIR COMPRESSOR369
INSTALLATION OF ENGINE ACCESSORY371
15 REPAIR AND REPLACEMENT OF PARTS 373
OUTLINE374
REPAIR GUIDE LINE374
WHEN SHOULD SUBSTITUTE REPAIRS BE CARRIED OUT374
INSPECTION374
TO ENSURE SAFETY, FOLLOW ALL INSTRUCTIONS IN MANUAL374
FOLLOW WASHING METHODS GIVEN IN MANUAL374
FOLLOW INSPECTION METHODS GIVEN IN MANUAL374
REPAIR METHODS FOR SCREWS USING COIL THREAD INSERT375
METHOD FOR USING TAPER THREAD PLUGS TO SEAL POCKETS AND SMALL HOLES IN CASTINGS376
REPAIR PROCEDURE376
METHOD FOR REPAIRING TAPER THREAD PLUG HOLES WORN BY LARGE SIZE COPPER PLATED PLUGS379
METHOD OF USING FILLER METAL IN EMERGENCY REPAIRS380
INSPECTION FOR REUSE OF CYLINDER BLOCK381
INSTALLATION OF EXPANSION PLUGS385
INSTALLATION OF PIPE PLUGS385
INSTALLATION OF EXPANSION PLUG TO CAMSHAFT HOLE388
REMOVAL OF CAMSHAFT BUSHING389
CLEANING OF CAMSHAFT BUSHING HOLE389
INSTALLATION OF CAMSHAFT BUSHING390
CLEANING AND INSPECTION OF CYLINDER LINERS BEFORE REUSING THEM393
CREANING OF CYLINDER LINERS393
INSPECTION OF CYLINDER LINERS394
CLEANING AND INSPECTION OF PISTON BEFORE REUSING IT396
REMOVE THE PISTON RINGS396
CLEANING OF PISTONS396
INSPECTION OF PISTONS397
CLEANING AND INSPECTION OF CRANKSHAFT BEFORE REUSING IT399
CLEANING OF CRANKSHAFT399
INSPECTION OF CRANKSHAFT399
REPLACEMENT OF CRANKSHAFT GEAR403
REMOVAL OF CRANKSHAFT GEAR403
INSPECTION OF CRANKSHAFT403
INSTALLATION OF CRANKSHAFT GEAR404
CLEANING AND INSPECTION OF MAIN BEARINGS BEFORE REUSING THEM406
GENERAL INFORMATION406
CLEANING OF MAIN BEARINGS406
INSPECTION OF MAIN BEARINGS406
INSPECTION OF THRUST BEARING407
CLEANING AND INSPECTION OF MAIN BEARING CAPS AND MOUNTING BOLTS BEFORE REUSING THEM408
CLEANING408
INSPECTION408
CLEANING AND INSPECTION OF CONNECTING ROD BEARINGS BEFORE REUSING THEM409
CLEANING OF CONNECTING ROD BEARINGS409
INSPECTION OF CONNECTING ROD BEARINGS409
CLEANING AND INSPECTION OF CONNECTING RODS BEFORE REUSING THEM411
CLEANING OF CONNECTING RODS411
INSPECTION OF CONNECTIONG RODS411
INSPECTION OF CONNECTING RODS FOR BEND AND TORSION414
CALIBRATION OF FIXING TOOL414
INSPECTION OF ALIGNMENT OF CONNECTING RODS415
REPAIR PROCEDURE FOR CONNECTING RODS415
REPLACEMENT OF CONNECTING ROD BUSHINGS416
REMOVAL416
INSTALLATION418
INSPECTION420
REPLACEMENT OF VALVE INSERTS OF CYLINDER HEAD421
REMOVAL421
INSPECTION423
ASSEMBLY423
INSPECTION OF VALVE GUIDES424
INSPECTION OF VALVE SEAT INSERTS425
INSPECTION OF VALVE SPRINGS426
INSPECTION OF VALVE STEM SEAL427
INSPECTION OF VALVES427
GRINDING OF VALVES428
GRINDING OF VALVE SEAT INSERTS429
ASSEMBLY433
INSTALLATION OF PIPE PLUGS433
REPLACEMENT OF VALVE GUIDES OF CYLINDER HEAD436
DISASSEMBLY436
INSPECTION436
ASSEMBLY436
CYLINDER HEAD-PRESSURE TEST439
VACUUM TEST ON VALVE SEATS OF CYLINDER HEAD441
CLEANING AND INSPECTION OF CYLINDER HEAD BOLTS443
CLEANING443
INSPECTION443
FREE LENGTH-MEASUREMENT444
IMAGES PREVIEW OF THE MANUAL:
S.M 16/12/24
