KOMATSU 114E-5 SERIES SERVICE REPAIR MANUAL (SEN05537-01) KOMATSU 114E 5 SERIES – PDF DOWNLOAD

SEN05537-01

ENGINE

114E

-5

SERIES

SHOP MANUAL

ENGINE 114E–5 SERIES Model

Serial Number

114E–5 SERIES

00 Index and foreword 1 00 Index and foreword

114E-5 SERIES

00-1

00 Index and foreword Index

Index

(ALL-0310-001-A-00-A)

00 Index and foreword ....................................................................................................................... 00-1 Index ......................................................................................................................................... 00-2 Foreword, safety and general information ..................................................................................... 00-5 Important safety notice ......................................................................................................... 00-5 How to read the shop manual.............................................................................................. 00-12 Explanation of terms for maintenance standard .................................................................... 00-14 Handling equipment of fuel system devices .......................................................................... 00-16 Handling of intake system parts........................................................................................... 00-17 Handling of hydraulic equipment.......................................................................................... 00-18 Method of disconnecting and connecting of push-pull type coupler ......................................... 00-20 Handling of electrical equipment.......................................................................................... 00-23 How to read electric wire code............................................................................................. 00-31 Precautions when performing operation ............................................................................... 00-34 Standard tightening torque table.......................................................................................... 00-39 List of abbreviation ............................................................................................................. 00-45 Conversion table ................................................................................................................ 00-50 01 Specification................................................................................................................................. 01-1 Table of contents ........................................................................................................................ 01-2 General information .................................................................................................................... 01-3 Exhaust gas regulation ......................................................................................................... 01-3 Specifications............................................................................................................................. 01-6 Applicable machines ............................................................................................................ 01-6 Specifications ...................................................................................................................... 01-7 General view ..................................................................................................................... 01-10 Engine performance curve .................................................................................................... 01-6 10 Structure and function ................................................................................................................... 10-1 Table of contents ........................................................................................................................ 10-2 Components layout..................................................................................................................... 10-3 Components layout drawing.................................................................................................. 10-3 Intake and exhaust system parts .................................................................................................. 10-5 Intake and exhaust system layout drawing ............................................................................. 10-5 Intake and exhaust system circuit diagram ............................................................................. 10-6 Air cleaner ........................................................................................................................... 10-8 KVGT.................................................................................................................................. 10-9 Aftercooler......................................................................................................................... 10-16 EGR system piping drawing ................................................................................................ 10-17 EGR system circuit diagram ................................................................................................ 10-19 EGR valve......................................................................................................................... 10-21 EGR cooler........................................................................................................................ 10-23 KCCV layout drawing ......................................................................................................... 10-25 KCCV ventilator ................................................................................................................. 10-28 KDPF................................................................................................................................ 10-32 Engine main body parts............................................................................................................. 10-36 Cylinder head .................................................................................................................... 10-36 Cylinder block .................................................................................................................... 10-38 Main moving parts.............................................................................................................. 10-40 Vibration damper................................................................................................................ 10-43 Timing gear ....................................................................................................................... 10-44 Front cover ........................................................................................................................ 10-45 Valve system ..................................................................................................................... 10-46 Flywheel............................................................................................................................ 10-47 Lubrication system.................................................................................................................... 10-48 Lubrication system parts layout drawing ............................................................................... 10-48 Lubrication system circuit diagram ....................................................................................... 10-50 Oil pump ........................................................................................................................... 10-51 Boost oil pump ................................................................................................................... 10-52 Oil filter.............................................................................................................................. 10-53 Oil cooler........................................................................................................................... 10-54

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00 Index and foreword Index

Regulator valve.................................................................................................................. 10-55 Safety valve....................................................................................................................... 10-56 Oil pan .............................................................................................................................. 10-57 Fuel system ............................................................................................................................. 10-58 Fuel system parts layout drawing......................................................................................... 10-58 Fuel system circuit diagram................................................................................................. 10-60 Supply pump ..................................................................................................................... 10-64 Pre-filter ............................................................................................................................ 10-68 Main filter .......................................................................................................................... 10-69 Cooling system......................................................................................................................... 10-70 Cooling system parts layout drawing.................................................................................... 10-70 Cooling system circuit diagram............................................................................................ 10-71 Drive pulley ....................................................................................................................... 10-73 Water pump....................................................................................................................... 10-77 Thermostat ........................................................................................................................ 10-78 Electrical equipment.................................................................................................................. 10-80 Alternator .......................................................................................................................... 10-80 Starting motor .................................................................................................................... 10-84 Intake air heater ................................................................................................................. 10-88 Engine wiring harness ........................................................................................................ 10-89 Engine controller ................................................................................................................ 10-91 Sensor .............................................................................................................................. 10-97 20 Standard value tables.................................................................................................................... 20-1 Table of contents ........................................................................................................................ 20-2 Standard service value table........................................................................................................ 20-3 Standard value table for engine ............................................................................................. 20-3 Running-in standard and performance test standard ............................................................... 20-9 50 Disassembly and assembly ........................................................................................................... 50-1 Table of contents ........................................................................................................................ 50-2 Related information on disassembly and assembly ........................................................................ 50-3 How to read this manual ....................................................................................................... 50-3 Coating materials list ............................................................................................................ 50-5 Special tool list..................................................................................................................... 50-9 Sketch of special tool.......................................................................................................... 50-11 Disassembly and assembly ....................................................................................................... 50-12 General disassembly of engine ........................................................................................... 50-12 General assembly of engine................................................................................................ 50-31 Removal and installation procedure of supply pump unit alone............................................... 50-70 Engine front oil seal replacement procedure ......................................................................... 50-74 Engine rear oil seal replacement procedure.......................................................................... 50-77 60 Maintenance standard................................................................................................................... 60-1 Table of contents ........................................................................................................................ 60-2 Intake and exhaust system parts .................................................................................................. 60-3 KVGT.................................................................................................................................. 60-3 Engine main body parts............................................................................................................... 60-4 Cylinder head ...................................................................................................................... 60-4 Cylinder block ...................................................................................................................... 60-6 Cylinder liner ....................................................................................................................... 60-8 Crankshaft......................................................................................................................... 60-10 Piston ............................................................................................................................... 60-12 Connecting rod .................................................................................................................. 60-13 Vibration damper................................................................................................................ 60-15 Timing gear ....................................................................................................................... 60-16 Camshaft .......................................................................................................................... 60-17 Valve and valve guide......................................................................................................... 60-19 Rocker arm........................................................................................................................ 60-21 Flywheel............................................................................................................................ 60-23 Lubrication system.................................................................................................................... 60-25 Oil pump ........................................................................................................................... 60-25 114E-5 SERIES

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00 Index and foreword Index

Index.................................................................................................................................................................... 1

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114E-5 SERIES

00 Index and foreword Foreword, safety and general information

Foreword, safety and general information Important safety notice

(ALL-0370-001-A-00-A)

(ALL-1120-012-A-01-A)

(Rev. 2012/10) • Appropriate servicing and repair are extremely important to ensure safe operation of the machine. The shop manual describes the effective and safe servicing and repair methods recommended by Komatsu.

Some of these methods require the use of the special tools designed by Komatsu for the specific purpose.

• The symbol mark k is used for such matters that require special cautions during the work. The work indicated by the caution mark should be performed according to the instructions with special attention to the cautions. Should hazardous situation occur or be anticipated during such work, be sure to keep safe first and take every necessary measure.

General precautions k Inappropriate

handling causes an extreme danger. Read and understand what is described in the operation and maintenance manual before operating the machine. Read and understand what is described in this manual before starting the work.

• Before performing any greasing or repairs, read all the safety labels stuck to the machine. For the locations of the safety labels and detailed explanation of precautions, see the operation and maintenance manual.

• Locate a place in the repair workshop to keep the tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt, water or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.

• When performing any work, always wear the safety shoes and helmet. Do not wear loose work cloths, or clothes with buttons missing.

•

•

•

•

1. Always wear the protective eyeglasses when hitting parts with a hammer.

2. Always wear the protective eyeglasses when grinding parts with a grinder, etc.

When performing any work with two or more workers, always agree on the working procedure before starting. While working, always keep conversations of the work between your fellow workers and your self on any step of the work.

During the work, hang the warning tag of "UNDER WORKING" in the operator's compartment.

Only qualified workers must perform the work and operation which require license or qualification.

Keep the tools in good condition. And learn the correct way to use the tools, and use the proper ones among them. Before starting the work, thoroughly check the tools, lift truck, service vehicle, etc.

If welding repairs is required, always have a trained and experienced welder with good

114E-5 SERIES

knowledge of welding perform the work. When performing welding work, always wear welding gloves, apron, shielding goggles, cap, etc.

• Before starting work, warm up your body thoroughly to start work under good condition.

• Avoid continuing work for long hours and take rests with proper intervals to keep your body in good condition. Take a rest in a specified safe place.

Safety points 1 2 3 4 5 6 7 8 9 10

Good arrangement Correct work clothes Observance of work standard Practice of making and checking signals Prohibition of operation and handling by unlicensed workers Safety check before starting work Wearing protective goggles (for cleaning or grinding work) Wearing shielding goggles and protectors (for welding work) Good physical condition and preparation Precautions against work which you are not used to or you are used to too much

Preparation • Before adding oil or making any repairs, place the machine on a firm and level ground, and apply the parking brake and chock the wheels or tracks to prevent the machine from moving.

• Before starting work, lower the work equipment (blade, ripper, bucket, etc.) to the ground. If it is not possible to lower the equipment to the ground, insert the lock pin or use blocks to prevent the work equipment from falling. And be sure to lock all the work equipment control levers and hang a warning tag on them.

• When performing the disassembling or assembling work, support the machine securely with blocks, jacks, or stands before starting the work.

• Remove all of mud and oil from the steps or other places used to get on and off the machine completely. Always use the handrails, ladders of

00-5

00 Index and foreword Foreword, safety and general information

steps when getting on or off the machine. Never jump on or off the machine. When the scaffold is not provided, use steps or stepladder to secure your footing.

Precautions during work • For the machine equipped with the battery disconnect switch, check that the system operating lamp is turned off before starting the work. Then, turn the battery disconnect switch to OFF (Q) position and remove the switch key. For the machine not equipped with the battery disconnect switch, remove the cable from the battery before starting the work. Be sure to remove the negative end (-) of the battery cable first.

• Release the remaining pressure in the circuits completely before the work when the parts in the circuits of oil, fuel, coolant and air are disconnected or removed. When the cap of the oil filter, drain plug or oil pressure pickup plug is removed, loose them slowly to prevent the oil from spurting out.

• When removing or installing the checking plug or the piping in the fuel circuit, wait 30 seconds or longer after the engine is shut down and start the work after the remaining pressure is released from the fuel circuit.

• Immediately after the engine is shut down, the coolant and oil in the circuits are hot. Be careful not to get scalded by the hot coolant and oil.

Start the work after checking that the coolant and oil are cooled down sufficiently.

• Start the work after the engine is shut down. Be sure to shut down the engine when working on or around the rotating parts in particular. When checking the machine without shutting down the engine (measuring oil pressure, rotational speed, oil or coolant temperature), take extreme care not to get caught in the rotating parts or the working equipment.

• The hoist or crane must be used to sling the components weighing 25 kg or heavier. Check the slings (wire rope, nylon sling, chain and hook) for damage before the work. Use the slings with ample capacity and install them to the proper places. Operate the hoist or crane slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane.

• When removing the part which is under internal pressure or reaction force of the spring, always leave 2 bolts in diagonal positions. Loosen those 2 bolts gradually and alternately and release the pressure, then, remove the part.

• When removing the part, be careful not to break or damage the electrical wiring. The damaged wiring may cause electrical fires.

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• When removing piping, prevent the fuel or oil from spilling out. If any fuel or oil drips onto the floor, wipe it off immediately. Fuel or oil on the floor can cause you to slip and can even cause fires.

• As a general rule, do not use gasoline to wash parts. Do not use gasoline to clean the electrical parts, in particular.

• Reinstall the parts removed to their original places. Replace the damaged parts and the parts which must not be used with new ones.

When installing the hoses and wiring harnesses, be careful that they are not damaged by contacting with other parts when the machine is operated.

• When connecting the high pressure hoses and tubes, make sure that they are not twisted. The damaged high pressure hoses and tubes are very dangerous when they are installed. So, be extremely careful when connecting the high pressure pipings. In addition, check that their connections are correct.

• When assembling or installing the parts, be sure to tighten the bolts to the specified torque. When installing the protective parts such as guards, or the parts which vibrate violently or rotate at high speeds, be sure to check that they are installed correctly.

• When aligning 2 holes, never insert your fingers or hand into the holes. Align the holes with care so that your fingers are not caught in the hole.

• When measuring hydraulic pressure, check that the measuring tools are correctly installed.

• Pay attention to safety when removing and installing the tracks of the track type machines.

When removing the track, it separates suddenly.

The workers should not stand at either end of the track.

• If the engine is operated for a long time in a closed place which is not ventilated well, you may suffer from gas poisoning. Accordingly, open the windows and doors to ventilate the place well.

Precautions for slinging work and making signals • Only one appointed worker must make signals and co-worker must communicate with each other frequently. The appointed signaler must make specified signals clearly at the place where the signaler is well seen from the operator's seat and where the signaler can see the working condition easily. The signaler must always stand in front of the load and guide the operator safely.

1. Do not stand under the load.

2. Do not step on the load.

• Check the slings before starting sling work.

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00 Index and foreword Foreword, safety and general information

• Keep putting on the gloves during sling work.

(Put on the leather gloves, if available.)

• Measure the weight of the load by the eye and check its center of gravity.

• Use the proper sling according to the weight of the load and method of slinging. If too thick wire ropes are used to sling a light load, the load may slip and fall.

• Do not sling a load with 1 wire rope only. If do so, the load may rotate or the sling gets loose and the sling may slip off. Install 2 or more wire ropes symmetrically.

• Apply wire ropes to the middle part of the hook. a Slinging near the tip of the hook may cause the rope to slip off the hook during hoisting.

The strength of the hook is maximum at its central part.

k Slinging

with one rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original slinging position on the load, which can result in a dangerous accident.

• Hanging angle must be 60 degrees or smaller as a rule.

• When hanging a heavy load (25kg or heavier), the hanging angle of the rope must be narrower than that of the hook. a When slinging a load with 2 ropes or more, the larger the hanging angle is, the larger the tension of each rope. The figure bellow shows the variation of allowable load in kg when hoisting is made with 2 ropes, each of which is allowed to sling up to 9.8 kN {1,000kg} a load vertically, at various hanging angles. When the 2 ropes sling a load vertically, up to 2000 kg of total weight can be suspended. This weight is reduced to 1000 kg when the 2 ropes make a hanging angle of 120 degrees. If the two ropes sling a 2000 kg load at a hanging angle of 150 degrees, each rope is subjected to a force as large as 4000 kg.

• Do not use twisted or kinked wire ropes.

• When slinging up a load, observe the following.

1. Wind up the rope slowly until the wire rope tensions. When putting your hands on the wire ropes, do not grasp them but press them down from above. If you grasp them, your fingers may be caught.

2. After the wire ropes are stretched, stop the crane and check the condition of the slung load, wire ropes, and pads.

3. If the load is unstable or the wire rope or chains are twisted, lower the load and lift it up again.

4. Do not lift up the load at an angle.

• When lowering a load, pay attention to the following.

1. When lifting down a load, stop it temporarily at 30 cm above the floor, and then lower it slowly.

2. Check that the load is stable, and then remove the sling.

3. Remove kinks and dirt from the wire ropes and chains used for the sling work, and put them in the specified place.

Precautions for using mobile crane a Read the Operation and Maintenance Manual of the crane carefully in advance and operate the crane safely.

Precautions for using overhead traveling crane k The

• When installing wire ropes to an angular load, apply pads to protect the wire ropes. If the load is slippery, apply proper material to prevent the wire rope from slipping.

• Use the specified eye bolts and fix wire ropes, chains, etc. to them with shackles, etc.

114E-5 SERIES

hoist or crane must be used to sling the components weighing 25 kg or heavier. A part weighing 25 kg or heavier in "disassembly and assembly" section is indicated with the symbol of 4 .

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00 Index and foreword Foreword, safety and general information

• Before starting work, check the wire ropes, brake, clutch, controller, rails, over winding prevention device, ground fault circuit interrupter for electric shock prevention, crane collision prevention device, and energizing warning lamp, and check the following safety items.

• Observe the signals for sling work.

• Operate the hoist at a safe place.

• Be sure to check the directions of the direction indication plate (north, south, east and west) and the operating button.

• Do not sling a load at an angle. Do not move the crane while the slung load is swinging.

• Do not raise or lower a load while the crane is moving longitudinally or laterally.

• Do not drag a sling.

• When lifting up a load, stop it just after it leaves the ground and check safety, and then lift it up.

• Consider the travel route in advance and lift up a load to a safe height.

• Place the control switch in a position where it will not be an obstacle to work and passage.

• After operating the hoist, do not swing the control switch.

• Remember the position of the main switch so that you can turn off the power immediately in an emergency.

• Shut down the main switch when the hoist stops because of a blackout. When turning on a switch which is turned OFF by the ground fault circuit interrupter for electric shock prevention, check that the devices related to that switch are not in operating condition.

• If you find an obstacle around the hoist, stop the operation.

• After finishing the work, stop the hoist at the specified position and raise the hook to at least 2 meters above the floor. Do not leave the sling attached to the hook.

Selecting wire ropes • Select adequate ropes depending on the weight of the parts to be hoisted, referring to the table below Wire rope (JIS G3525, 6 x 37 - Type A) (Standard Z twist wire ropes without galvanizing) Nominal diameter of rope mm 10 12 14 16 18 20 25 30 40

00-8

Allowable load kN 8.8 12.7 17.3 22.6 28.6 35.3 55.3 79.6 141.6

ton 0.9 1.3 1.7 2.3 2.9 3.6 5.6 8.1 14.4

Nominal diameter of rope mm 50 60

Allowable load kN 221.6 318.3

ton 22.6 32.4

a The allowable load is calculated as one sixth of the breaking load of the rope to be used (safety coefficient: 6).

Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit Disconnection k When

replacing the air conditioner unit, air conditioner compressor, condenser or receiver drier, etc., collect the refrigerant (air conditioner gas: R134a) from the air conditioner circuit before disconnecting the air conditioner hoses.

a Ask a qualified person for collecting, adding and filling operations of the refrigerant (air conditioner gas: R134a). (Only registered persons can work.) a Never release the refrigerant (air conditioner gas: R134a) to the atmosphere. k If

refrigerant gas (air conditioner gas: R134a) gets in your eyes, you may lose your sight.

And if it touches your skin, you may suffer from frostbite. Put on protective eyeglasses, gloves and working clothes with long sleeves while collecting the refrigerant or filling the air conditioner circuit with the refrigerant.

• When loosening the nuts fixing air conditioner hoses and tubes, be sure to use 2 wrenches; use one wrench to fix and use the other one to loosen the nut.

Connection • When installing the hose for the air conditioner circuit, take care not to allow invasion of dirt, dusts and water into the hose.

• Check that the O-rings are fitted to the joints when connecting the air conditioner piping.

• Once an O-ring is used, it is deformed and deteriorated. Accordingly, do not reuse it.

• When removing the O-rings, use a soft tool so that the piping is not damaged.

• Check that the O-ring is not damaged or deteriorated.

• Apply compressor oil for refrigerant (R134a) to the O-ring. a However, do not apply oil to the threaded portion of a bolt, nut or union.

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00 Index and foreword Foreword, safety and general information

Manufacturer DENSO VALEO THERMAL SYSTEMS SANDEN

Part name ND-OIL8 ZXL100PG (equivalent to PAG46) SP-10

• When tightening nuts of the air conditioner hoses and tubes, be sure to use 2 wrenches.

Use one wrench to fix and tighten the nut with the other wrench to the specified torque (Use a torque wrench for tightening). a Example of fitting of O-ring • An O-ring is fitted to every joint of the air conditioner piping.

For tightening torques, see "Others", "Precautions for disconnection and connection of air conditioner piping".

114E-5 SERIES

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00 Index and foreword Foreword, safety and general information

Precautions to prevent fire

(ALL-0000-17B-K-03-A)

• Fire caused by fuel, oil, coolant or window washer fluid Do not bring any flame or fire close to flammable substances such as fuel, oil, coolant or window washer fluid.There is danger that they may catch fire. Always observe the following.

• Do not smoke or use any flame near fuel or other flammable substances.

• Shut down the engine before adding fuel.

• Do not leave the machine when adding fuel or oil.

• Tighten all the fuel and oil caps securely.

• Be careful not to spill fuel on overheated surfaces or on parts of the electrical system.

• After adding fuel or oil, wipe up any spilled fuel or oil.

• Put greasy rags and other flammable materials into a safe container to maintain safety at the workplace.

• When washing parts with oil, use a nonflammable oil. Do not use diesel oil or gasoline.There is danger that they may catch fire.

• Do not weld or use a cutting torch to cut any pipes or tubes that contain flammable liquids.

• Determine well-ventilated areas for storing oil and fuel. Keep the oil and fuel in the specified place and do not allow unauthorized persons to enter.

• When performing grinding or welding work on the machine, move any flammable materials to a safe place before starting.

•

•

•

9 J D 0 1 7 2 0

•

9 J D 0 1 7 2 1

• Fire caused by accumulation or attachment of flammable material

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• Remove any dry leaves, chips, pieces of paper, coal dust, or any other flammable materials accumulated or attached to or around the engine exhaust manifold, muffler, or battery, or on the undercovers.

• To prevent fires from being caught, remove any flammable materials such as dry leaves, chips, pieces of paper, coal dust, or any other flammable materials accumulated around the cooling system (radiator, oil cooler) or on the undercover.

Fire coming from electric wiring Short circuits in the electrical system can cause fire. Always observe the following.

• Keep all the electric wiring connections clean and securely tightened.

• Check the wiring every day for looseness or damage. Reconnect any loose connectors or refasten wiring clamps. Repair or replace any damaged wiring.

Fire caused by piping Check that all the clamps for the hoses and tubes, guards, and cushions are securely fixed in position.

If they are loose, they may vibrate during operation and rub against other parts.There is danger that this may lead to damage to the hoses and cause high-pressure oil to spurt out, leading to fire and serious personal injury or death.

Fire around the machine due to highly heated exhaust gas This machine is equipped with KDPF (Komatsu Diesel Particulate Filter).

KDPF is a system for purifying soot in exhaust gas.Its exhaust gas discharged during purification process (regeneration) can be at higher temperature than that from existing models. Do not bring any flammable material close to the outlet of the exhaust pipe.

• When there are thatched houses, dry leaves or pieces of paper near the work site, set the system to disable the regeneration before starting work to prevent fire hazards due to highly heated exhaust gas.

See the operation and maintenance manual for the setting procedure.

Explosion caused by lighting equipment • When checking fuel, oil, battery electrolyte, or coolant, always use lighting equipment with anti-explosion specifications.

• When taking the electrical power for the lighting equipment from the machine itself, follow the instructions in the operation and maintenance manual.

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Action if fire occurs

(ALL-0000-17A-K-01-A)

• Turn the starting switch to OFF position to stop the engine.

• Use the handrails and steps to get off the machine.

• Do not jump off the machine. You may fall or suffer serious injury.

• The fume generated by a fire contains harmful materials which have a bad influence on a human body when they are sucked.

Don't breathe a fume.

• After a fire, there may be harmful compounds left. If it touches your skin it may have a bad influence on your body.

Be sure to wear rubber gloves when handle the materials left after the fire.

The material of the gloves, which is recommended is polychloroprene (Neoprene) or polyvinyl chloride (in the lower temperature environment).

When wearing cotton-work-gloves, wear rubber gloves under them.

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How to read the shop manual

(ALL-0320-010-A-03-A)

(Rev. 2012/10) • Some attachments and optional parts described in this shop manual may not be arranged for certain areas. Contact your Komatsu distributor if one or some of them are required.

• Materials and specifications are subject to change without notice.

• The shop manuals are available for "Machine part" and "Engine part". For the engine, see the shop manual for the same model of the engine as the one which is mounted on the machine.

Composition of shop manual • This shop manual describes the technical information required for the services performed in a workshop.

The shop manual is divided into the following chapters for the convenience of use.

00. Index and foreword • This section includes the index, foreword, safety and basic information.

01. Specification • This section explains the specifications of the machine.

10. Structure and function • This section explains the structure and function of the machine. The section of "Structure and function" serves not only to give an understanding for the structure of each component, but also serves as reference material for troubleshooting.

20. Standard value table • The standard values for a new machine and trouble shooting are described. This standard value table is used for testing and adjusting, and determining a failure at troubleshooting.

50. Disassembly and assembly • This section explains the procedures for removing, installing, disassembling, and assembling each part or component and the special tools for the works as well as precautions for doing them safely. In addition, tightening torque, and quantity and weight of coating material, oil, grease, and coolant required for the works are also explained.

60. Maintenance standard • This section describes the maintenance standard values for each component. This section gives the criterion values for each component and required remedy at disassembly or maintenance.

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00 Index and foreword Foreword, safety and general information

Symbol Important safety and quality portions are marked with the following symbols so that the shop manual is used practically.

Symbol

Item

k

Safety

a

Caution

4

Weight

3

Tightening torque

2

Coat

5

Oil, coolant

6

Drain

Remarks The special safety precautions required for performing work are described.

The special technical precautions or other precautions for preserving standards required when performing work are described The weight of part or component and the cautions required when selecting hoisting wire or when working posture is important are indicated.

The tightening torques that require special attention during assembly work are indicated.

The places to be coated with adhesives, grease, etc. during assembling are indicated.

The places where oil, coolant, etc. must be added and the quantity to be added are indicated.

Places where oil, coolant, etc. must be drained and the quantity to be drained are indicated.

Unit • In this shop manual, the units are indicated with International System of units (SI). • For reference, Gravitational System of units which is used to be used is indicated in parentheses of { }.

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Explanation of terms for maintenance standard

(ALL-0330-006-A-01-A)

(Rev. 2012/10) • The chapter of maintenance standard shows judgement criteria to determine the products to be replaced or to be reused. The judgement criteria are described by using the following terms.

Standard dimension and tolerance • To be accurate, the finished dimension of a part is slightly different from one to another.

• The finished dimension of a part specifies the allowable difference from the standard dimension which is set first.

• The dimension set as the standard is called the standard dimension and the range of difference from this standard dimension is called the "tolerance".

• An indication example of a standard dimension and tolerance is shown in the following table.

(The standard dimension is entered on the left side and the tolerance is entered with a positive or negative symbol on the right side) Example: Standard dimension

Tolerance -0.022 -0.126

120

• The tolerance may be indicated in the text and a table as "standard dimension (upper limit of tolerance/lower limit of tolerance)."

Example: 120(-0.022/-0.126) • Usually, the dimension of a hole and the dimension of a shaft to be inserted into the hole are indicated by the same standard dimension and different tolerances of the hole and shaft.

The tightness of fit is decided by the tolerance.

• An indication example of a shaft and hole is shown in the following table.

(The standard dimension is entered on the left side and the tolerance of the shaft is entered with a positive or negative symbol at the center and that of the hole on the right side) Standard dimension 60

Tolerance Shaft -0.030 -0.076

Hole +0.046 0

Standard clearance and standard value • The clearance made when new parts are assembled is called the standard clearance, which is indicated by the range from the minimum clearance to the maximum clearance.

• When some parts are repaired, the clearance is generally adjusted to the standard clearance.

• The values indicating performance and function of new products or equivalent are called the "standard value", which is indicated by a range or a target value.

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• When some parts are repaired, the value of performance/function is set to the standard value.

Standard interference • When the diameter of a hole of a part shown in the given standard dimension and tolerance table is smaller than that of the shaft to be inserted, the difference between those diameters is called the "interference".

• Subtract the maximum dimension of the hole from the minimum dimension of the shaft and call it (A). Subtract the minimum dimension of the hole from the maximum dimension of the shaft and call it (B). The range between (A) and (B) is the "standard interference".

• After repairing or replacing some parts, measure the dimension of their hole and shaft and check that the interference is in the standard range.

Repair limit and allowable value or allowable dimension • The dimensions of parts change because of the wear or deformation while they are used. When the dimension changes exceeding certain value,

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the parts can not be used any longer. This value is called "repair limit".

• If a part is worn to the repair limit, it must be replaced or repaired.

• The performance and function of the products lower while they are used. When the value of the performance and function lowers exceeding a certain limit and it influences the operation etc., this value is called the allowable value or allowable dimension.

• A product whose dimension is out of the allowable value, must be repaired. However, since the allowable values are generally estimated through various tests or experiences in most cases, the judgement must be made in consideration of the operating condition and customer's requirement.

Allowable clearance • Parts can be used until the clearance between them is increased to a certain limit. The limit at which those parts cannot be used is called the "allowable clearance".

• If the clearance between the parts exceeds the allowable clearance, they must be replaced or repaired.

Allowable interference • The allowable maximum interference between the hole of a part and the shaft of another part to be assembled is called the "allowable interference".

• The allowable interference shows the repair limit of the part of smaller tolerance.

• The parts whose interferences are out of the allowable interference must be replaced or repaired.

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Handling equipment of fuel system devices

(PC-AD00-2A4-K-00-A)

(Rev. 2012/01) • The common rail fuel injection system (CRI) consists of more precise parts than the parts used in the conventional fuel injection pump and nozzle. If foreign material enters this system, it may cause a failure. Use special care to prevent entry of the foreign material when servicing the fuel system.

Use care for working environment • Avoid filter change or repairing the machine in rain or high winds, or at places where there is a lot of dust.

Sealing openings • Plug the pipes and the openings of the components which are removed with the caps, tapes, vinyl bags, etc. to prevent foreign material from entering. Never perform repair works under the condition that the openings are left as they are or plugged with cloths as foreign material may enter or environment may be polluted by the oil leaked. Do not discard the waste oil somewhere or other. Hand it over to your customer for disposal, or dispose it by yourself.

How to clean parts when dirt is stuck • If any dirt or dust sticks the parts of the fuel system, clean it off thoroughly with clean fuel.

Precautions for replacing fuel filter cartridge • Be sure to use the Komatsu genuine fuel filter cartridge.

• The common rail fuel injection system (CRI) consists of more precise parts than the parts used in the conventional fuel injection pump and nozzle. In order to prevent foreign material from entering this system, the filter employs a specially high performance of filter element. If a filter element other than the genuine one is used, the fuel system may have a failure. Accordingly, never use such a filter element.

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Handling of intake system parts

(PC220-A900-2A4-K-00-A)

(Rev.2012/01) • The Komatsu Variable Geometry Turbocharger (KVGT) consists of more precise parts (variable mechanism) than the parts used in the conventional turbocharger. If foreign material enters this system, it may cause a failure. Use special care to prevent entry of the foreign material when servicing the air intake system.

Be careful of working environment • Avoid the repair work of the machine in rain or strong wind or at the places where there is a lot of dust.

Sealing openings • Plug the pipes and the openings of the components which are removed, with the caps, tapes, vinyl bags, etc. to prevent foreign material from entering. Never perform repair works under the condition that the openings are left open or plugged with rag since foreign material may enter.

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Handling of hydraulic equipment

(ALL-C000-2A4-P-01-A)

(Rev. 2012/10) • With the increase in pressure and precision of the hydraulic components, the most common cause of a failure is dirt (foreign material) in the hydraulic circuit. Therefore, the special care must be taken when adding hydraulic oil,or when disassembling or assembling the hydraulic components.

Be careful of working environment • Avoid adding hydraulic oil, replacing filters, or repairing the machine in rain or high winds, or at places where there is a lot of dust.

Disassembly and maintenance work in the field • When disassembly or maintenance work of the hydraulic is performed in the field, there is danger of dust entering the components. It is also difficult to check the performance of the components after repairs, so it is desirable to use the component exchange service. The disassembly and assembly of the hydraulic components must be performed in the specially arranged dustproof workshop and the performance test of the components must be performed with the special testing equipment.

Plugging of opening (prevention of flowing out of oil) • Plug the pipes and the openings of the components which are removed (when plugs are not prepared, seal with caps, tapes, vinyl bags, etc.) to prevent entry of foreign material and flowing out of oil. Never leave the openings of the pipes and hoses without being covered or plugged with cloth as foreign material may enter them or environment may be polluted by the oil leaked. Do not discard the waste oil somewhere or other. Hand it over to your customer for disposal, or dispose it by yourself.

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Preventing intrusion of foreign materials during refilling operations.

• Care must be taken when adding hydraulic oil so that foreign material does not enter. Keep the oil filler port and the area around it, oil supply pump and oil container clean. If an oil cleaning device is used, it is possible to remove the dirt that is collected during storage. It is a surer means.

Replacing hydraulic oil while its temperature is high • When the hydraulic oil is warm, it flows easily. In addition, sludge can also be drained from the circuit together with the oil. So, it is better to change the hydraulic oil while it is warm. When changing the hydraulic oil, the old oil must be drained as much as possible. (Drain the oil not only from the hydraulic tank, but also from the filter housing and the drain plug hole in the circuit.) If the old oil is left in the system, the contaminant and sludge in the oil mix with the new oil and shorten the life of the new hydraulic oil.

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Flushing operations • After disassembling the equipment or when changing the hydraulic oil with new one, flush the system to remove the contaminant and sludge left in the hydraulic circuit as well as the oil which includes them. Normally, flushing is performed twice. Primary flushing is performed by use of the flushing oil and the secondary flushing is performed by use of the specified hydraulic oil.

Cleaning operations • After repairing the hydraulic equipment (pump, control valve, etc.) or when the machine is in operation, perform oil cleaning to remove the sludge or contaminant in the hydraulic oil circuit.

The oil cleaning equipment can remove the ultra fine (approximately 3 μm) particles that the filter built in the hydraulic equipment can not remove.

So, it is an extremely effective device.

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Method of disconnecting and connecting of push-pull type coupler

(ALL-

C930-001-P-00-A)

(Rev. 2012/01) k Loosen

the oil filler cap of the hydraulic tank slowly to release the remaining pressure in the hydraulic tank.

k Even

if the remaining pressure is released from the hydraulic tank, some hydraulic oil flows out when the hose is disconnected. Accordingly, prepare an oil container.

Type 1

(ALL-C930-925-P-01-A)

Disconnection 1. Hold adapter (1) and push hose joint (2) into mating adapter (3). (Fig. 1) a It can be pushed in by approximately 3.5mm. a Do not hold rubber cap portion (4).

2. While pushing hose joint (2) into adapter (3), push rubber cap (4) against adapter (3) until "click" is heard. (Fig. 2) 3. Hold hose adapter (1) or hose (5) and pull it out.

(Fig. 3) a Since some hydraulic oil flows out, prepare an oil container.

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Connection 1. Hold hose adapter (1) or hose (5) and insert it in mating adapter (3) aligning them with each other.

(Fig. 4) a Do not hold rubber cap part (4).

2. After inserting the hose fitting in the adapter on the other side perfectly, pull it back to check the connecting condition. (Fig. 4) a When the hose fitting is pulled back, the rubber cap will move toward the hose, however, it is not a problem.

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Type 2

(ALL-C930-925-P-02-A)

Disconnection 1. While holding the fitting, push body (7) in straight until sliding prevention ring (6) hits contact surface (a) at the hexagonal part on the male side. (Fig. 6) 2. While keeping the condition of Step 1, turn lever (8) to the right (clockwise). (Fig. 7) 3. While keeping the conditions of Steps 1 and 2, pull out whole body (7) to disconnect it. (Fig. 8)

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Connection 1. While holding the fitting, push body (7) in straight until sliding prevention ring (6) hits contact surface (a) at the hexagonal part on the male side to connect it. (Fig. 9)

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Type 3

(ALL-C930-925-P-03-A)

Disconnection 1. While holding the fitting, push body (9) in straight until sliding prevention ring (8) hits contact surface (b) at the hexagonal portion on the male side. (Fig. 10) 2. While keeping the condition of Step 1, push cover (10) straight until it hits contact surface (b) of the hexagonal portion on the male side. (Fig. 11) 3. While keeping the conditions of Steps 1 and 2, pull out whole body (9) to disconnect it. (Fig. 12)

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Connection 1. While holding the fitting, push body (9) in straight until sliding prevention ring (8) hits contact surface (a) at the hexagonal portion on the male side to connect them. (Fig. 13)

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Handling of electrical equipment

(ALL-E000-2A4-P-01-A)

(Rev. 2012/11) • To maintain the performance of the machine over a long period, and to prevent failures or troubles before they occur, correct "operation", "maintenance and inspection" "troubleshooting", and "repairs" must be performed. This section deals particularly with correct repair procedures for mechatronics components and is aimed at improving the quality of repairs. For this purpose, it describes the working procedures in "Handling of electrical equipment".

Precautions for handling electric equipment Handling wiring harnesses and connectors • Wiring harnesses consist of wires connecting one component to another component, connectors used for connecting and disconnecting one wire from another wire, and protectors or tubes used for protecting the wires.

• Compared with other electrical components fitted in boxes or cases, wiring harnesses are 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 to suffer deformation or damage. For this reason, it is necessary to be extremely careful when handling the wiring harnesses.

Main failures occurring in wiring harness Defective contact of connectors (defective contact between male and female connectors) • Problems with defective contact are likely to occur because the male connector is not properly inserted into the female connector,or because one or both of connectors are deformed or the position is not correctly aligned, or because there is corrosion or oxidization of the contact surfaces. The corroded or oxidized contact surfaces may become shiny again (and contact may become normal) by connecting and disconnecting the connectors approximately 10 times.

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Defective crimping or soldering of connectors • The pins of the male and female connectors are attached to wires by crimping or soldering. If excessive force is applied to the wire, the joining area may become loose, which may result in a defective connection or breakage.

Disconnections in wiring • If the wiring harness is pulled to disconnect the connector, or the components are lifted with a crane while the wiring harness is still connected, or a heavy object hits the wiring harness, the crimping of the connector may separate, or the soldering may be damaged, or the wiring harness may be broken.

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blow it with compressed air and spray it with electrical contact restorer. a When wiping the joint portion of the connector, be careful not to apply excessive force or deform the pins. a If there is oil or water in the compressed air, it causes the contacts to become dirtier. So, remove the oil and water from the compressed air completely before cleaning the connector with the compressed air.

High-pressure water entering connector • The connector is designed to make it difficult for water to enter (drip-proof structure), but if highpressure water is sprayed directly on the connector, water may enter the connector, depending on the direction of the water jet.

Accordingly, take care not to spray water over the connector.

The connector is designed to prevent water from entering, but once water does enter, it is difficult to drain it. If water should get into the connector, the pins will be short-circuited by the water. So if any water gets in, immediately dry the connector or take other appropriate action before passing electricity through it.

Removing, installing, and drying connectors and wiring harnesses Disconnecting connectors 1. Hold the connectors when disconnecting.

• Disconnect connectors by holding the connector bodies. For the connectors held by a screw, loosen the screw fully, then hold the male and female connectors with each hand respectively and pull them apart horizontally.

For the connectors with lock stopper, press down the stopper with your thumb and pull the connectors apart. a Never pull the connector with one hand.

Entry of water, mud or dirt when disconnecting a connector • If any water, mud or dirt is stuck to the outside surface of a connector, it can enter inside the connector when the connector is disconnected.

Before disconnecting the connector, wipe off any stuck water or dirt by using a piece of dry cloth or blow it with compressed air.

Oil, mud or dirt stuck to connector • If any oil or grease is stuck to the connector and an oil film is formed on the mating surface of the male and female pins, the oil prevents electricity from passing through, resulting in defective contact. If any oil or grease, mud or dirt is stuck to the connector, wipe it off with a dry cloth or

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2. When removing from clips • Both of the connector and clip have stoppers, which are engaged with each other when the connector is connected.

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• Check that there is no oil, dirt or water stick to the connector pins (joint portion).

• Check that the connector pins are free from deformation, defective contact, corrosion, or damage.

• Check that external surfaces of the connectors are free from damage or breakage.

• When removing a connector from a clip, pull the connector in a parallel direction to the clip for removing stoppers. a If the connector is pried up and down or to the right and left, the housing may break.

a If any oil, water or dirt is stuck to the connector, wipe it off with a dry cloth. If any water is inside the connector, warm the connector and the inside of the wiring harness with a dryer. But be careful not to make it too hot as it causes short circuit. a If there is any damage or breakage, replace the connector.

2. Fix the connector securely.

• Align the connectors correctly, and fit them securely. For the connectors with the lock stopper, push in the connectors until "click" is heard.

3. Action to take after removing connectors • After removing the connector, cover it with the vinyl bag to prevent entry of dust, dirt,oil or water in the contact portion. a If the machine is left disassembled for a long time, it is particularly easy for improper contact to occur, so always cover the connector.

3. Correct the protrusion of the boot and misalignment of the wiring harness • For connectors fitted with the boot, correct any extrusion of the boot. In addition, if the wiring harness or the clamp is out of the position, put it in its original position. a If the connector cannot be corrected easily, remove the clamp and adjust the position.

Connecting connectors 1. Check the connector visually.

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• If the connector clamp is removed, be sure to return it to its original position. And check that it is securely installed.

Drying wiring harness • If there is any oil or dirt on the wiring harness, wipe it off with a dry cloth. Avoid washing by using steam. If the wire harness must be washed in water, do not apply high pressure water or steam directly to the wiring harness. If water gets directly on the connector, do as follows.

1. Disconnect the connector and wipe off the water with a dry cloth. a If the connector is to be blown with dry compressed air, there is a risk that oil in the air may cause defective contact of the conditioner, remove oil and water in the air before starting air blow.

Handling of Deutsch connector (DT8-pin, DT12pin) Disconnection 1. While pressing locks (a) and (b) from each side respectively, pull out female connector (2).

2. Dry the inside of the connector with a dryer.

If water gets inside the connector, use a dryer to dry the connector.

Connection 1. Push in female connector (2) horizontally until the lock clicks. (Arrow: x) 2. Since locks (a) and (b) may not be set completely, push in female connector (2) with curving movement until the locks are set normally. (Arrow: x, y, and z)

a Hot air from the dryer can be used, but regulate the time to use hot air in order to prevent the connector or related parts from becoming too hot, as it causes deformation or damage to the connector.

a Lock (a) in the figure is pulled down (not set completely), and lock (b) is set completely.

3. Perform a continuity test on the connector.

After drying, leave the wiring harness disconnected and perform a continuity test to check for any short circuits between pins caused by water. a After the connector is completely dried, blow the contact restorer and reassemble them.

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Handling of connectors used on engine

2. While pressing lock (L2), pull out connector (1).

Slide, lock type (FRAMATOME-3, FRAMATOME-2) Disconnection 1. Slide lock (L1) to the right.

2. While pressing lock (L2), pull out connector (1) toward you. a In the case that even if lock (L2) is pressed, connector (1) cannot be pulled out toward you unless part A floats, float part A with a small flat-head screwdriver while pressing lock (L2), and then pull out connector (1) toward you.

a Lock (L2) is located in the back of connector (1).

Connection 1. Insert the connector securely until a click is heard.

(FRAMATOME-24) Disconnection 1. Slide down lock (red) (L1).

Connection 1. Insert the connector securely until a click is heard.

Pull lock type (PACKARD-2) Disconnection 1. Disconnect the connector (2) by pulling lock (B) (on the wiring harness side) of connector (2) outward.

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Connection 1. Insert the connector securely until a click is heard.

Push lock type (BOSCH-3) Disconnection 1. While pressing lock (C), pull out connector (3) in the direction of the arrow.

Connection 1. Insert the connector securely until a click is heard.

(AMP-3) Disconnection 1. While pressing lock (E), pull out connector (5) in the direction of the arrow.

• 114 series

Connection • 107 series

1. Insert the connector securely until a click is heard.

(SUMITOMO-2) Disconnection 1. While pressing lock (E), pull out connector (5) in the direction of the arrow.

a If the lock is located on the underside, use flat-head screwdriver [1] since you cannot insert your fingers.

While pushing up lock (C) of the connector with flat-head screwdriver [1], pull out connector (3) in the direction of the arrow.

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Connection 1. Insert the connector securely until a click is heard.

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(SUMITOMO-3) Disconnection 1. While pressing lock (E), pull out connector (5) in the direction of the arrow. a Pull the connector straight up.

Connection 1. Insert the connector to the end while aligning its grove to the other.

2. Turn housing (H1) in the direction of the arrow until it "clicks".

Connection 1. Insert the connector securely until a click is heard.

(SUMITOMO-4) Disconnection 1. While pressing lock (D), pull out connector (4) in the direction of the arrow.

Handling controller • The electronic circuits for control including the microcomputers are assembled in the controller.

These electronic circuits in the controller must be handled with care as they control the machine.

• Do not place objects on top of the controller.

Connection 1. Insert the connector securely until a click is heard.

Turn-housing type (Round green connector) (CANNON-4) Disconnection 1. Turn housing (H1) in the direction of the arrow. a Unlock the connector by turning housing (H1).

When the lock is release the housing is felt tight to turn.

2. Pull out housing (H1) in the direction of the arrow. a Housing (H1) is left on the wiring harness side.

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• Cover the control connectors with tape or a vinyl bag. Never touch the connector contacts.

• During rainy weather, do not leave the controller in a place where it is exposed to rain.

• Do not place the controller on oil, water, or soil, or in a place that can be heated to a high

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temperature even for a short period of time.

(Place it on a suitable dry stand.)

• Precautions when performing arc welding When performing arc welding on the machine body, disconnect all the wiring harness connectors connected to the controller. Put the arc welding ground to the place close to the welding point.

Precautions for troubleshooting electrical circuits • Be sure to turn the starting switch to the "OFF" position before disconnecting or connecting the connectors.

• Before performing troubleshooting, check all the related connectors for loose connection. a Check the related connectors for their performance by disconnecting and connecting them several times.

• Be sure to connect all the disconnected connectors before proceeding to the next step. a If the starting switch is turned to the "ON" position with the connectors disconnected, the failure which is not related to the part which is actually failed.

• When performing the troubleshooting for the circuit (measurement of voltage, resistance, continuity, current, etc.), shake the related wiring harnesses and connectors several times and check that the multimeter reading does not change. a If there is any value change on the multimeter, there may be a defective contact in the circuit.

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How to read electric wire code

(ALL-E500-030-P-00-A)

(Rev. 2012/10) • In the electrical circuit diagram, material, thickness and color of each electric wire are indicated by symbols. The wire code is helpful in understanding the electrical circuit diagram.

Example) AEX 0.85 L: Indicates blue, heat-resistant, low-voltage wire for automobile, having nominal No. of 0.85 Indicates type of wire by symbol.

Type, symbol, and material of wire are shown in Table 1.

AEX (Since the use of AV and AVS wires depends on size (nominal No.), their symbols are not indicated on the diagram.)

Indicates size of wire by nominal No. 0.85 Size (Nominal No.) is shown in Table 2.

Indicates color of wire by color code.

L Color codes are shown in Table 3.

Type, symbol, and material • AV and AVS are different in thickness and outside diameter of the coating. CAVC has a circular compressed conductor. It differs from AV and AVS in the outside diameter of conductor and thickness of the coating. And AEX is similar to AV in thickness and outside diameter of the coating but different from AV and AVS in material of the coating.

(Table 1) Type

Symbol

Low-voltage wire for AV automobile Thin-cover low-voltage wire for AVS automobile (Type 1) Thin-cover low-voltage wire for CAVS automobile (Type 2) Heatresistant lowvoltage wire AEX for automobile

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Conductor material

Insulator material

Temperature range (°C) in use

Example of use For large current wiring (nominal No. 5 and above)

Soft polyvinyl chloride

-30 to +60

Annealed copper for electric appliance

General wiring (nominal No. 3 and lower)

For mid- to small-size excavators (nominal No. 1.25 and lower)

Heat-resistant cross linked polyethylene

-50 to +110

General wiring for extremely cold weather specification Wiring at high ambient temperature place

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Dimensions (Table 2)

Coating D

(0.5) 0.75f (0.85) 1.25f (1.25) Nominal No. 0.5f Number of strands/ 20/ 30/ 11/ 50/ 16/ 7/0.32 Diameter of 0.18 0.18 0.32 0.18 0.32 strand Conductor Crosssectional 0.51 0.56 0.76 0.88 1.27 1.29 area (mm2) d (approx.)

1.0 1.2 1.5 AVS Standard 2.0 2.2 2.5 — — — AV Standard AEX

Standard

2.0

2.2

2.7

2f

2

3f

3

5

37/ 0.26

26/ 0.32

58/ 0.26

41/ 0.32

65/ 0.32

1.96

2.09

3.08

3.30

5.23

1.9 2.9 —

1.9 2.9 —

2.3 3.5 —

2.4 3.6 —

3.0 — 4.6

3.0

3.1

—

3.8

4.6

Coating D

Nominal No. 8 15 20 30 40 Number of strands/ 50/0.45 84/0.45 41/0.80 70/0.80 85/0.80 Diameter of strand Conductor Crosssectional 7.95 13.36 20.61 35.19 42.73 area (mm2) d (approx.)

3.7 4.8 6.0 8.0 8.6 — — — — — AVS Standard AV Standard 5.5 7.0 8.2 10.8 11.4 AEX

Standard

Coating D

Nominal No. Number of strands/ Diameter of strand Conductor Crosssectional area (mm2) d (approx.)

CAVS

Standard

5.3

7.0

8.2

10.8

50

60

85

100

108/ 0.80

127/ 0.80

169/ 0.80

217/ 0.80

54.29

63.84

84.96

109.1

9.8 — 13.0

10.4 — 13.6

12.0 — 16.0

13.6 — 17.6

13.0

13.6

16.0

17.6

11.4

0.5f

0.5

0.75f

0.85

1.25f

1.25

—

7/round compression

—

11/round compression

—

16/round compression

—

0.56

—

0.88

—

1.29

—

0.9

—

1.1

—

1.4

—

1.6

—

1.8

—

2.1

a "f" of nominal No. denotes "flexible".

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Color codes table (Table 3) Color Code B Br BrB BrR BrW BrY Ch Dg G GB GL Gr GR GW GY L LB Lg LgB LgR

Color of wire Black Brown Brown & Black Brown & Red Brown & White Brown & Yellow Charcoal Dark green Green Green & Black Green & Blue Gray Green & Red Green & White Green & Yellow Blue Blue & Black Light green Light green & Black Light green & Red

Color Code LgW LgY LR LW LY O P R RB RG RL RW RY Sb Y YB YG YL YR YW

Color of wire Light green & White Light green & Yellow Blue & Red Blue & White Blue & Yellow Orange Pink Red Red & Black Red & Green Red & Blue Red & White Red & Yellow Sky Blue Yellow Yellow & Black Yellow & Green Yellow & Blue Yellow & Red Yellow & White

a Remarks: In a color code consisting of 2 colors, the first color is the color of the background and the second color is the color of the marking.

Examples) GW means that the background is "Green" and marking is "White".

Types of circuits and color codes Type of wire Charge Ground Start Light Instrument Signal Type of circuit Others

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R B R RW Y G L Br Lg O Gr P Sb Dg Ch

WG — — RB YR GW LW BrW LgR — — — — — —

AVS, AV, CAVS — — — — — — RY RG YB YG GR GY LR LY BrR BrY LgY LgB — — — — — — — — — — — —

AEX — — — RL YL GB LB BrB LgW — — — — — —

— — — — YW GL — — — — — — — — —

R B R D Y G L — — — — — — — —

— — — — Gr Br — — — — — — — — —

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Precautions when performing operation

(ALL-1160-927-A-00-A)

(Rev. 2012/11) • When performing "testing and adjusting" of the machine, "removal and installation" and "disassembly and assembly" of the components, observe the following general cautions.

Precautions for removal and disassembly work • If the cooling water contains coolant, dispose of it correctly as chemicals. Do not drain it to the sewage rashly.

• After disconnecting the hoses or tubes, plug them to prevent dirt or dust from entering.

• When draining oil, prepare a container with sufficient capacity.

• Check the match marks which indicate the installing position, and put match marks on the places where they seem necessary before removal of the components to prevent any mistake when assembling.

• To prevent any excessive force from being applied to the wiring, always hold the connectors when disconnecting the connectors. Do not pull the wires.

• Attach the tags to wires and hoses to show their installing positions to prevent any mistake when installing.

• Check the number and thickness of the shims, and keep them in a safe place.

• When hoisting the components, prepare the slings with sufficient strength.

• When using forcing screws to remove any component, tighten the forcing screws uniformly and alternately.

• Before removing any component, clean the surrounding area and cover the component to prevent any foreign material from entering after removal.

• After disconnecting the piping or removing a pipe joint, install the following plugs. a The O-rings in the table are emergency parts used for disassembly or transportation of the machine.

When assembling, confirm the part numbers in the parts book and use the parts conforming to the using condition.

Disconnection of face seal type hoses and tubes

Nominal No. 02 03 04 05 06

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Hose side Plug (1) 07376-70210 07376-70315 07376-70422 07376-70522 07376-70628

Pipe joint side Nut (2) 02789-00210 02789-00315 02789-00422 02789-00522 02789-00628

O-ring (3) 02896-11008 02896-11009 02896-11012 02896-11015 02896-11018

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Disconnection of taper seal type hoses and tubes

Nominal No. 02 03 04 05 06 10 12 14

Hose side Plug (1) 07376-50210 07376-50315 07376-50422 07376-50522 07376-50628 07376-51034 07376-51234 07376-51443

Pipe joint side Nut (2) 07222-00210 07222-00312 07222-00414 07222-00515 07222-00616 07222-01018 07222-01219 07222-01422

Disconnection of split flange type hoses and tubes

No- Bolt pitch (mm) Hose side minal a Flange (1) b No. 0737904 38.1 17.5 00400 0737905 42.9 19.8 00500 0737906 47.6 22.2 00640 0737910 52.4 26.2 01044 0737958.7 30.2 01250 12 0737966.7 31.8 01260 0737914 69.9 35.8 01460

114E-5 SERIES

Tube side Split flange Sleeve head O-ring (4) (2) (3) 07371-30400 07378-10400 07000-12021 07371-30500 07378-10500 07000-13022 07371-30640 07378-10600 07000-13025 07371-31049 07378-11000 07000-13032 07371-31255 07378-11200 07000-13038 07371-51260 07378-11210 07000-13038 07371-31465 07378-11400 07000-13048

Bolt (5) 0101080825 0101080830 0737251035 0737251035 0737251035 0101081245 0737251240

Washer (6) 01643-50823 01643-50823 01643-51032 01643-51032 01643-51032 01643-51232 01643-51232

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No- Bolt pitch (mm) Hose side minal a Flange (1) b No. 0737979.4 36.5 01470 0737977.8 42.8 02071 20 0737996.8 44.5 02080 0737924 88.9 50.8 02484 0737930 106.4 62 03010 34

120.6

69.8

40

130.2

77.8

50

152.4

92

Tube side Split flange Sleeve head O-ring (4) (2) (3)

Bolt (5)

07371-51470 07378-11410 07000-13048 07371-32076 07378-12000 07000-12060 07371-52080 07378-12010 07000-12060 07371-12484 07378-12400 07000-12070 07371-13010 07378-13000 07000-12085

07379-03411 07371-13411 07378-13400 07000-12100 0737904012

07371-14012 07378-14000 07000-12110

07379-05011 07371-15011 07378-15000 07000-12135

0101081455 0737251240 0101081865 0737251240 0737251650 0737251650 0737251650 0737251655

Washer (6) 01643-31445 01643-51232 01643-31845 01643-51232 01643-51645 01643-51645 01643-51645 01643-51645

Removal of pipe joints of O-ring boss type

Nominal No. 08 10 12 14 16 18 20 24 30 33 36 42 52

Plug (1) 07040-10807 07040-11007 07040-11209 07040-11409 07040-11612 07040-11812 07040-12012 07040-12412 07041-13012 07040-13316 07041-13612 07040-14220 07040-15223

O-ring (2) 07002-10823 07002-11023 07002-11223 07002-11423 07002-11623 07002-11823 07002-12034 07002-12434 07002-13034 07002-13334 07002-13634 07002-14234 07002-15234

Removal of pipe joints of taper pipe thread type

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Nominal No. 01 02 03 04 06 10 12 14 20

Nominal thread size R 1/ 8 R 1/ 4 R 3/ 8 R 1/ 2 R 3/ 4 R1 R1 1/4 R1 1/2 R2

Plug (1) Square head type (A) 07042-00108 07042-00211 07042-00312 07042-00415 07042-00617 07042-01019 07042-01222 07042-01422 07042-02026

Hexagonal socket head (B) 07043-00108 07043-00211 07043-00312 07043-00415 07043-00617 07043-01019 07043-01222 07043-01422 07043-02026

Precautions for installation and assembly work • Tighten the bolts and nuts (sleeve nuts) to the specified torque (KES), unless otherwise specified.

• Install the hoses without twist and interference, and securely fasten the clamps located in-between if they are.

• Replace all of the gaskets, O-rings, cotter pins, and lock plates with new parts.

• Bend the cotter pins and lock plates securely.

• When applying adhesive, clean and degrease the part, and apply 2 to 3 drops of adhesive to the threaded portion.

• When applying liquid gasket, clean and degrease the surface, and apply it uniformly after making sure that the surface is free from dirt or damage.

• Clean all of the parts, and repair any damage, dents, burrs, or rust found on them.

• Coat the rotating parts and sliding parts with engine oil.

• Coat the surfaces of the press-fitting parts with molybdenum disulfide lubricant (LM-P).

• After installing the snap ring, check that the snap ring is settled in the ring groove completely.

• When connecting wiring harness connectors, clean the connectors to remove oil, dirt, or water, then connect them securely.

• Use the eye bolts with no fatigue and deformation and screw them in securely. Match the directions of the eyes and the hook.

• When installing split flanges, tighten the bolts uniformly and alternately to prevent excessive tightening on one side.

• As a rule, apply liquid gasket (LG-5) or liquid sealant (LS-2) to the threaded portion of each taper male screws which receives pressure.

However, if the threaded portion is difficult to degrease, you may use a seal tape.

• When winding a seal tape onto a right-handed taper male screw, wind it clockwise in the advancing direction of the threads, seeing from the screw end and starting at the third thread. a If you wind the seal tape in the opposite direction, it becomes loose and comes off or its end part is pushed out, and that can cause oil leakage.

114E-5 SERIES

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00 Index and foreword Foreword, safety and general information

a When the hydraulic cylinder is used for the first time after reassembly of the hydraulic equipment such as the hydraulic cylinder, pump, etc. and piping after removing them for repair, be sure to perform air bleeding of the hydraulic circuit according to the following procedure.

1. Start and run the engine at low idle.

2. Repeat the operation to extend and retract each cylinder of the work equipment to approximately 100 mm before the stroke end 4 to 5 times.

3. Operate the hydraulic cylinder 3 to 4 times to the end of its stroke. a After the completion of repair and when operating the machine which is stored long term, perform the air bleeding with the same procedure as the one described above.

Precautions at the time of completing work Refilling of coolant, oil and grease • When the coolant is drained, tighten the drain valve securely, then refill the coolant reservoir with the coolant Komatsu recommends to the specified level. Start the engine to circulate the coolant in the piping, and add the coolant to the specified level again.

• When the hydraulic components are removed and installed, refill the oil reservoir with the oil Komatsu recommends to the specified level. Start the engine to circulate the oil in the piping, and add the oil to the specified level again.

• If the hydraulic piping or hydraulic equipment is removed, be sure to bleed air from the system after rebuilding the parts, by referring to "Testing and adjusting".

• Supply the specified amount of grease to the work equipment parts.

Testing installed condition of cylinder heads and manifolds • Check the cylinder head and intake and exhaust manifold mountings for looseness.

• If any bolt is loose, retighten it. a For the tightening torques, see the "Disassembly and assembly".

Testing of engine piping for damage and looseness Check the piping for damage, the mounting bolts and nuts for looseness, and the joints Intake and exhaust for air suction and exhaust gas leakage. system If any part is loosely installed or damaged, retighten the bolts or repair the parts.

Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for water leakage.

Cooling system If any part is loosely installed or damaged, retighten the bolts or repair the parts.

Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel leakage.

Fuel system If any part is loosely installed or damaged, retighten the bolts or repair the parts.

Check of KDPF or muffler and exhaust pipe for damage and looseness • Visually check the KDPF or muffler, exhaust pipe and their mounting parts for a crack and damage. If any part is damaged, replace it.

• Check the mounting bolts, nuts, and clamps of the KDPF or muffler, exhaust pipe and their mounting parts for looseness.

If any part is loosely installed, retighten the bolts.

Check of KDPF or muffler function • Check the KDPF or the muffler for unusual noise comparing to the noise when they are new.

If any unusual noise is heard, repair KDPF or muffler, referring to "Troubleshooting" and "Disassembly and assembly".

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114E-5 SERIES

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Standard tightening torque table

(ALL-M140-03B-P-01-A)

(Rev. 2012/10) Table of tightening torque for bolts and nuts Unless otherwise specified, tighten the metric bolts and nuts to the torque shown in the table below.

Thread diameter (mm) 6 8 10 12 14 16 18 20 22 24 27 30 33 36 39

Width across flats (mm) 10 (*2) 10 13 (*2) 12 17 (*1, *2) 14 19 (*1, *2) 17 22 24 (*1) 22 27 30 32 36 41 46 50 55 60

Tightening torque (Nm {kgm}) 11.8 to 14.7 {1.2 to 1.5} 27 to 34 {2.8 to 3.5} 59 to 74 {6.0 to 7.5} 98 to 123 {10.0 to 12.5} 157 to 196 {16 to 20} 245 to 309 {25 to 31.5} 343 to 427 {35 to 43.5} 490 to 608 {50 to 62} 662 to 829 {67.5 to 84.5} 824 to 1,030 {84 to 105} 1,180 to 1,470 {120 to 150} 1,520 to 1,910 {155 to 195} 1,960 to 2,450 {200 to 250} 2,450 to 3,040 {250 to 310} 2,890 to 3,630 {295 to 370}

*1: Split flange bolt. *2: Flanged bolt.

114E-5 SERIES

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00 Index and foreword Foreword, safety and general information

a Tighten the following flanged bolt on which "7" is stamped on its top to the tightening torque shown in the following table.

Thread diameter (mm) 6 8 10 12

Width across flats (mm) 10 12 14 17

Tightening torque (Nm {kgm}) 5.9 to 9.8 {0.6 to 1.0} 13.7 to 23.5 {1.4 to 2.4} 34.3 to 46.1 {3.5 to 4.7} 74.5 to 90.2 {7.6 to 9.2}

Unless otherwise specified, tighten the unified coarse threaded bolts and nuts to the torque shown in the table below.

Type of bolt Nominal No. threads per inch, type of thread 1/4-20UNC 5/16-18UNC 3/8-16UNC 7/16-14UNC 1/2-13UNC 9/16-12UNC 5/8-11UNC 3/4-10UNC 7/8-9UNC 1-8UNC 1 1/8-7UNC 1 1/4-7UNC 1 1/2-6UNC

00-40

A Tightening torque (Nm {kgm})

B Tightening torque (Nm {kgm})

Range

Target

Range

Target

9.8 to 14.7 {1 to 1.5} 24.5 to 34.3 {2.5 to 3.5} 44.1 to 58.8 {4.5 to 6} 73.5 to 98.1 {7.5 to 10} 108 to 147 {11 to 15} 157 to 216 {16 to 22} 226 to 294 {23 to 30} 392 to 530 {40 to 54} 637 to 853 {65 to 87} 883 to 1,196 {90 to 122} 1,187 to 1,608 {121 to 164} 1,598 to 2,157 {163 to 220} 2,354 to 3,177 {240 to 324}

12.7 {1.3} 29.4 {3} 52.0 {5.3} 86.3 {8.8} 127 {13} 186 {19} 265 {27} 461 {47} 745 {76} 1,040 {106} 1,393 {142} 1,873 {191} 2,765 {282}

2.9 to 3.9 {0.3 to 0.4} 6.9 to 8.8 {0.7 to 0.9} 9.8 to 14.7 {1 to 1.5} 19.6 to 24.5 {2 to 2.5} 29.4 to 39.2 {3 to 4} 44.1 to 58.8 {4.5 to 6} 63.7 to 83.4 {6.5 to 8.5} 108 to 147 {11 to 15} 177 to 235 {18 to 24} 245 to 333 {25 to 34} 333 to 451 {34 to 46} 451 to 608 {46 to 62} 657 to 892 {67 to 91}

3.43 {0.35} 7.8 {0.8} 11.8 {1.2} 21.6 {2.2} 34.3 {3.5} 51.0 {5.2} 68.6 {7} 127 {13} 206 {21} 284 {29} 392 {40} 530 {54} 775 {79}

114E-5 SERIES

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Unless otherwise specified, tighten the unified fine threaded bolts and nuts to the torque shown in the table below.

Type of bolt Nominal No. threads per inch, type of thread 1/4-28UNF 5/16-24UNF 3/8-24UNF 7/16-20UNF 1/2-20UNF 9/16-18UNF 5/8-18UNF 3/4-16UNF 7/8-14UNF 1-14UNF 1 1/8-12UNF 1 1/4-12UNF 1 1/2-12UNF

A Tightening torque (Nm {kgm})

B Tightening torque (Nm {kgm})

Range

Target

Range

Target

14.7 to 19.6 {1.5 to 2} 34.3 to 39.2 {3.5 to 4} 53.9 to 68.6 {5.5 to 7} 83.4 to 108 {8.5 to 11} 127 to 167 {13 to 17} 186 to 245 {19 to 25} 255 to 343 {26 to 35} 441 to 598 {45 to 61} 716 to 961 {73 to 98} 1,020 to 1,373 {104 to 140} 1,353 to 1,844 {138 to 188} 1,804 to 2,432 {184 to 248} 2,707 to 3,658 {276 to 373}

17.7 {1.8} 37.3 {3.8} 61.8 {6.3} 96.1 {9.8} 147 {15} 216 {22} 294 {30} 520 {53} 843 {86} 1,196 {122} 1,598 {163} 2,118 {216} 3,177 {324}

3.9 to 4.9 {0.4 to 0.5} 7.8 to 9.8 {0.8 to 1} 14.7 to 19.6 {1.5 to 2} 24.5 to 29.4 {2.5 to 3} 34.3 to 49.0 {3.5 to 5} 49.0 to 68.6 {5 to 7} 73.5 to 98.1 {7.5 to 10} 127 to 167 {13 to 17} 196 to 265 {20 to 27} 284 to 382 {29 to 39} 382 to 520 {39 to 53} 510 to 686 {52 to 70} 765 to 1,030 {78 to 105}

4.41 {0.45} 8.8 {0.9} 16.7 {1.7} 26.5 {2.7} 41.2 {4.2} 58.6 {6} 83.4 {8.5} 147 {15} 226 {23} 333 {34} 451 {46} 598 {61} 892 {91}

Table of tightening torque for O-ring boss piping joints a Unless otherwise specified, tighten the pipe joint for O-ring boss to the torque shown in the table below.

Nominal No. 02 — 03, 04 05, 06 114E-5 SERIES

Thread diameter (mm) 14 18 20 24

Width across flats (mm) Varies depending on type of connector.

Tightening torque (Nm {kgm}) Range

Target

35 to 63 {3.5 to 6.5} 59 to 98 {6.0 to 10.0} 84 to 132 {8.5 to 13.5} 128 to 186 {13.0 to 19.0}

44 {4.5} 78 {8.0} 103 {10.5} 157 {16.0}

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00 Index and foreword Foreword, safety and general information

Nominal No. 10, 12 14

Thread diameter (mm) 33 42

Width across flats (mm)

Tightening torque (Nm {kgm}) Range

Target

363 to 480 {37.0 to 49.0} 746 to 1,010 {76.0 to 103}

422 {43.0} 883 {90.0}

Table of tightening torque for O-ring boss plugs a Unless otherwise specified, tighten the plug for O-ring boss to the torque shown in the table below.

Nominal No. 08 10 12 14 16 18 20 24 30 33 36 42 52

Thread diameter (mm) 8 10 12 14 16 18 20 24 30 33 36 42 52

Width across flats (mm) 14 17 19 22 24 27 30 32 32 — 36 — —

Tightening torque (Nm {kgm}) Range

Target

5.88 to 8.82 {0.6 to 0.9} 9.8 to 12.74 {1.0 to 1.3} 14.7 to 19.6 {1.5 to 2.0} 19.6 to 24.5 {2.0 to 2.5} 24.5 to 34.3 {2.5 to 3.5} 34.3 to 44.1 {3.5 to 4.5} 44.1 to 53.9 {4.5 to 5.5} 58.8 to 78.4 {6.0 to 8.0} 93.1 to 122.5 {9.5 to 12.5} 107.8 to 147.0 {11.0 to 15.0} 127.4 to 176.4 {13.0 to 18.0} 181.3 to 240.1 {18.5 to 24.5} 274.4 to 367.5 {28.0 to 37.5}

7.35 {0.75} 11.27 {1.15} 17.64 {1.8} 22.54 {2.3} 29.4 {3.0} 39.2 {4.0} 49.0 {5.0} 68.6 {7.0} 107.8 {11.0} 127.4 {13.0} 151.9 {15.5} 210.7 {21.5} 323.4 {33.0}

Table of tightening torque for hose (taper seal type and face seal type) a Unless otherwise specified, tighten the hose fittings (taper seal type and face seal type) to the torque shown in the table below. a The table is applied to the threads coated with engine oil (wet threads)

00-42

114E-5 SERIES

00 Index and foreword Foreword, safety and general information

Nominal No. of hose

Width across flats (mm)

02

19

03 04 05 06 (10) (12) (14)

22 24 27 32 36 41 46 55

Tightening torque (Nm {kgm})

Taper seal

Range

Target

34 to 54 {3.5 to 5.5} 34 to 63 {3.5 to 6.5} 54 to 93 {5.5 to 9.5} 59 to 98 {6.0 to 10.0} 84 to 132 {8.5 to 13.5} 128 to 186 {13.0 to 19.0} 177 to 245 {18.0 to 25.0} 177 to 245 {18.0 to 25.0} 197 to 294 {20.0 to 30.0} 246 to 343 {25.0 to 35.0}

44 {4.5} 44 {4.5} 74 {7.5} 78 {8.0} 103 {10.5} 157 {16.0} 216 {22.0} 216 {22.0} 245 {25.0} 294 {30.0}

Face seal Nominal No. - Thread root diameter Thread size threads per (mm) inch, type of (mm) (reference) thread 9/16-18UN — 14.3 — — 14 11/16-16UN — 17.5 — — 18 13 /16-16UN 20.6 22 24 1 -14UNS 25.4 30 1 3/16-12UN 30.2 — — 33 — — 36 — — 42

Table of tightening torque for face seal joints a The tightening torque table below applies to the seal joint (sleeve nut type) a The table is applied to the threads coated with engine oil (wet threads).

Width Outer diameter of across flats (mm) pipe (mm) 8 10 12 15 {16} 22 {20}

19 22 24 {27} 30 {32} 36

Tightening torque (Nm {kgm}) Range

Target

14 to 16 {1.4 to 1.6} 24 to 27 {2.4 to 2.7} 43 to 47 {4.4 to 4.8} 60 to 68 {6.1 to 6.8} 90 to 95 {9.2 to 9.7}

15 {1.5} 25.5 {2.6} 45 {4.6} 64 {6.5} 92.5 {9.4}

Face seal Nominal No. Thread root threads per inch, diameter (mm) type of thread (reference) 9/16-18UN 14.3 11/16-16UN 17.5 13/16-16UN 20.6 1 -14UNS 25.4 30.2 1 3/16-12UN

Reference: The face seal joint of the dimension in ( ) is also used, depending on the specification.

Tightening torque table for bolts and nuts on 102,107 and 114 series engines a Unless otherwise specified, tighten the metric threads bolts and nuts used on the 102, 107 and 114 series engines to the torques shown in the table below.

Thread diameter (mm) 6 8 10 12 14

114E-5 SERIES

Tightening torque (Nm {kgm}) 10 ± 2 {1.02 ± 0.20} 24 ± 4 {2.45 ± 0.41} 43 ± 6 {4.38 ± 0.61} 77 ± 12 {7.85 ± 1.22} —

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00 Index and foreword Foreword, safety and general information

Tightening torque table for 102, 107, and 114 series engines (joint bolts) a Unless otherwise specified, tighten the metric joint bolts used on the 102, 107, and 114 series engines to the torque shown in the table below.

Thread diameter (mm) 6 8 10 12 14

Tightening torque (Nm {kgm}) 8 ± 2 {0.81 ± 0.20} 10 ± 2 {1.02 ± 0.20} 12 ± 2 {1.22 ± 0.20} 24 ± 4 {2.45 ± 0.41} 36 ± 5 {3.67 ± 0.51}

Tightening torque table for tapered screws on 102,107, and 114 series engines (National taper pipe thread (NPT)) a Unless otherwise specified, tighten the National taper pipe threaded (NPT) screws used on the 102, 107, and 114 series engines to the torques shown in the table below.

Material of female screw Nominal thread size 1/16 1/ 8 1/ 4 3/ 8 1/ 2 3/ 4

00-44

In cast iron or steel Tightening torque (Nm {kgm}) 15 ± 2 {1.53 ± 0.20} 20 ± 2 {2.04 ± 0.20 25 ± 3 {2.55 ± 0.31} 35 ± 4 {3.57 ± 0.41} 55 ± 6 {5.61 ± 0.61} 75 ± 8 {7.65 ± 0.82}

In aluminum Tightening torque (Nm {kgm}) 5 ± 1 {0.51 ± 0.10} 15 ± 2 {1.53 ± 0.20} 20 ± 2 {2.04 ± 0.20} 25 ± 3 {2.55 ± 0.31} 35 ± 4 {3.57 ± 0.41} 45 ± 5 {4.59 ± 0.51}

114E-5 SERIES

00 Index and foreword Foreword, safety and general information

List of abbreviation

(ALL-0360-005-A-00-A)

(Rev. 2013/03) • This list of abbreviations includes the abbreviations used in the text of the shop manual for parts, components, and functions whose meaning is not immediately clear. The spelling is given in full with an outline of the meaning.

• Abbreviations that are used in general society may not be included.

• Special abbreviations which appear infrequently are noted in the text (marked with a).

• This list of abbreviations consists of 2 parts. The first part is a list of the abbreviations used in the text of the manual, and the second part is a list of the abbreviations used in the circuit diagrams.

List of abbreviations used in the shop manual Abbreviation

ABS

AISS

AJSS

ARAC

ARSC

ASR ATT BCV CAN CDR

CLSS

CRI

ECM

Actual word spelled out

Purpose of use (major applicable machine (*), or equipment/device)

Explanation

With this function, when the tires skid (wheels stop rotating), the brakes are released, and when the wheels start to rotate, the brakes are applied again.

Automatic Idling This function automatically sets the idle Engine Setting System speed.

A lever is used to perform the steering Steering operations instead of a steering wheel.

Advanced Joystick Steering System Moreover, it shifts gear and changes direction (WA) (FORWARD or REVERSE).

When the accelerator pedal is released while Travel and brake the machine is traveling downhill, this function Automatic Retarder automatically applies the retarder with a Accelerator Control (HD, HM) constant braking force.

When the accelerator pedal is released while the machine is traveling downhill, this function Travel and brake Automatic Retarder automatically applies the retarder to ensure Speed Control (HD, HM) that the machine speed does not accelerate above the speed set by the operator.

When the tires spin on soft ground surfaces, Travel and brake Automatic Spin this function automatically uses the optimum Regulator (HD, HM) braking force to drive both wheels.

A device that can be fixed onto a machine in Work equipment Attachment order to enable it to do different jobs.

When the retarder is not being used, this Brake Brake cooling oil valve bypasses part of the brake cooling oil to control valve (HD) reduce the load on the hydraulic pump.

Controller Area Communication and One of communication standards that is used Network electronic control in the network on the machine.

A regulator valve which is installed to KCCV Crankcase Depression Engine ventilator. It is written as CDR valve and it is Regulator not used independently.

This system can simultaneously actuate multiple actuators regardless of the load Closed-center Load Hydraulic system (provides better combined operation than O.L. Sensing System S.S.).

Engine controller electronically controls supply pump, common rail, and injector. This Common Rail Injection Engine function maintains optimum fuel injection amount and fuel injection timing.

Electronic control device uses the signals from the sensors on the machine. This signal Electronic Control Electronic control system indicates the optimum actuation to the Module actuators. (Same as E.C.U.) Anti-skid Brake System

114E-5 SERIES

Travel and brake (HD, HM)

00-45

00 Index and foreword Foreword, safety and general information

Abbreviation ECMV

ECSS

ECU

EGR

EMMS EPC

FOPS

F-N-R GNSS GPS

HSS

Actual word spelled out

Purpose of use (major applicable machine (*), or equipment/device)

Proportional electromagnetic valve that gradually increases oil pressure to engage clutch and reduces transmission shock.

This system ensures smooth high-speed Electronically Travel travel by absorbing vibration of machine Controlled Suspension during travel with hydraulic spring effect of (WA) System accumulator.

Electronic control device uses the signals from the sensors on the machine. This signal Electronic Control Unit Electronic control system indicates the optimum actuation to the actuators. (Same as E.C.M.) This function recirculates part of exhaust gas Exhaust Gas to combustion chamber in order to reduce Engine Recirculation combustion temperature, controls emission of NOx. This system allows data (filter, oil replacement Equipment interval, malfunctions on machine, failure Management Machine monitor code, and failure history) from each sensor on Monitoring System the machine to be checked on the monitor.

Electromagnetic This mechanism allows actuators to be Hydraulic system Proportional Control operated in proportion to the current supplied.

This structure protects the operator's head from falling objects. (Falling Object Protective Falling Object Structure) Cab and canopy Protective Structure This performance is standardized as ISO 3449.

Forward-NeutralOperation Forward-Neutral-Reverse Reverse Global Navigation A general term for positioning system using Communication Satellite System satellites such as GPS, GALILEO, etc.

Communication Global Positioning This system uses satellites to determine the (KOMTRAX, KOMTRAX current location on the earth.

System Plus) This function uses a combination of hydraulic motor and bevel shaft to control difference in Steering Hydrostatic Steering travel speed of right and left tracks.

System (D) Accordingly machine can turn without using Electronic Control Modulation Valve

Transmission (D, HD, WA, etc.)

HST

Hydro Static Transmission

Transmission (D, WA)

ICT

Information and Communication Technology

Intelligent Machine Control

IMA

Inlet Metering Actuator Engine

IMU

Inertial Measurement Unit

Intelligent Machine Control

IMV

Inlet Metering Valve

Engine

KCCV

00-46

Explanation

Komatsu Closed Engine Crankcase Ventilation

steering clutch.

This function uses a combination of hydraulic pump and hydraulic motor to shift the speed range steplessly without using gears.

A general term for the engineering and its socially applied technology of information processing and communication.

This valve is installed at inlet port of pump, and it adjusts fuel intake amount in order to control fuel discharge of supply pump. Same as I.M.V. This is a device to detect the angular velocity and acceleration of the 3 axes that control motions.

This valve is installed at inlet port of pump, and it adjusts fuel intake amount in order to control fuel discharge of supply pump. Same as I.M.V. (I.M.A.) This mechanism separates oil in blowby gas and returns it to the intake side to afterburn it there. It primarily consists of filters.

114E-5 SERIES

00 Index and foreword Foreword, safety and general information

Abbreviation

Actual word spelled out

Purpose of use (major applicable machine (*), or equipment/device)

KCSF

Komatsu Catalyzed Soot Filter

Engine

KDOC

Komatsu Diesel Oxidation Catalyst

Engine

KDPF

Komatsu Diesel Particulate Filter

Engine

KTCS

Komatsu Traction Control System

Travel and brake (HM system)

KVGT

Komatsu Variable Geometry Turbocharger

Engine

LCD

Liquid Crystal Display

Machine monitor

LED

Light Emitting Diode

Electronic parts

LIN

Local Interconnect Network

Communication and electronic control

LS

Load Sensing

Hydraulic system

LVDS

Low Voltage Differential Signaling

Communication and electronic control

MAF

Mass Air Flow

Engine

MMS

Multimedia Messaging Communication Service

NC

Normally Closed

Electric and hydraulic systems

NO

Normally Open

Electric and hydraulic systems

Open-center Load Sensing System

Hydraulic system

Pressure Compensation

Hydraulic system

OLSS PC

PCCS

PCV

Palm command control Steering system (D) Pre-stroke Control Valve

114E-5 SERIES

Engine

Explanation This filter captures soot in exhaust gas.

It is built in to KDPF. The catalyst used for purifying exhaust gas.

This is built in KDPF or assembled with the muffler.

This component is used to purify the exhaust gas. KDOC (catalyst) and KCSF (filter to capture soot) are built-in it.

It is installed in place of the conventional muffler.

This function recovers the drive force of the wheels by braking automatically with the optimum force and at the same time activates the inter-axle differential lock when the wheels idle while the machine travels on the soft ground road.

The turbocharger on which the cross-section area of the exhaust passage is made variable.

Image display equipment such as a monitor which assembles in the liquid crystal element.

It refers to semiconductor element that emits light when the voltage is applied in forward direction.

One of communication standards that is used in the network on the machine Function that detects differential pressure of pump and controls discharge amount corresponding to load.

One of communication standards that is used in the network on the machine This indicates engine intake air flow.It is not used independently but it is used as combined with sensor.Mass air flow sensor can be called as MAF sensor.

Service that allows transmission and reception of short messages consisting of characters or voice or images between cell phones.

Device actuated to open electric or hydraulic circuits that are normally closed if not actuated.

Device actuated to close electric or hydraulic circuits that are normally open if not actuated.

Hydraulic system that can operate multiple actuators at the same time, regardless of the load.

A function used to correct oil pressure.

System in which a controller instantly analyses data from each lever, pedal, and dial, and performs optimum electronic control of the engine and transmission.

This valve is installed at inlet port of pump and it adjusts fuel intake amount in order to control fuel discharge amount of supply pump.

00-47

00 Index and foreword Foreword, safety and general information

Abbreviation PPC PPM PTO PTP

ROPS

SI

Actual word spelled out

Purpose of use (major applicable machine (*), or equipment/device)

Proportional Pressure Hydraulic system Control Piston Pump and Motor Power Take Off Power Tilt and power Pitch dozer

Hydraulic system (D, PC, etc.)

Power transmission Work equipment (D)

Roll-Over Protective Structure

Cab and canopy

Le Systeme International d’ Unites Unit (International unit system)

SOL

Solenoid

Electric system

TWV

2-Way Valve

Hydraulic and electric systems

VFT

Variable Flow Turbocharger

Engine

Explanation Used for controlling proportional pressure.

This system moves actuators in proportion to the oil pressure.

Piston pump and motor.

Power take-off mechanism This function performs hydraulic control of the tilt and pitch of the bulldozer blade.

If a machine tips over, this structure protects the operator with the seat belt fastened from being crushed. (Operator Protective Structure When Tipping) This performance is standardized as ISO 3471.

Abbreviation for the "International System of Units". It is the universal unit system and "a single unit for a single quantity" is the basic principle applied.

It refers to an actuator consisting of a solenoid and an iron core that is moved by the magnetic force when the solenoid is energized.

Solenoid valve that switches over direction of flow.

Turbocharger variable in route of exhaust passage.

*1: Code for applicable machine family D: Bulldozer HD: Dump truck HM: Articulated dump truck PC: Hydraulic excavator WA: Wheel loader List of abbreviations used in the circuit diagrams Abbreviation A/C A/D A/M ACC ADD AUX BR CW CCW ECU ECM ENG EXGND F.G. GND IMA NC

00-48

Actual word spelled out Air Conditioner Analogue-to-Digital Air Mix Damper Accessory Additional Auxiliary Battery Relay Clockwise Counter Clockwise Electronic Control Unit Electronic Control Module Engine External Ground Frame Ground Ground Inlet Metering Actuator No Connection 114E-5 SERIES

00 Index and foreword Foreword, safety and general information

Abbreviation S/T STRG SIG SOL STD OPT OP PRESS SPEC SW TEMP T/C T/M

114E-5 SERIES

Actual word spelled out Steering Signal Solenoid Standard Option Pressure Specification Switch Temperature Torque Converter Transmission

00-49

00 Index and foreword Foreword, safety and general information

Conversion table

(ALL-2150-931-A-00-A)

(Rev. 2012/10) Method of using the conversion table • The unit conversion table enables the simple conversion in the figures between the different units. For further details of the method of use of the conversion table, see the examples given below.

Example: Method of using the conversion table to convert a unit from millimeters to inches Conversion of 55 mm into inches 1. Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a horizontal line from (A).

2. Locate the number 5 in the row across the top, take this as (B), then draw a vertical line down from (B).

3. Take the point where the 2 lines cross as (C). This point (C) gives the value when converting the unit from millimeters to inches. Therefore, 55 mm = 2.165 in.

Conversion of 550 mm into inches 1. The number 550 does not appear in the table, so divide it by 10 (move the decimal point one place to the left) to get 55 mm.

2. Then convert 55 mm to 2.165 in by the same procedure as above.

3. The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point one place to the right) to get the original value. This gives 550 mm = 21.65 in. Therefore, 550 mm = 21.65 in.

Millimeters to inches (B)

(A)

00-50

0 10 20 30 40

0 0 0.394 0.787 1.181 1.575

1 0.039 0.433 0.827 1.220 1.614

2 0.079 0.472 0.866 1.260 1.654

3 0.118 0.512 0.906 1.299 1.693

4 0.157 0.551 0.945 1.339 1.732

50 60 70 80 90

1.969 2.362 2.756 3.150 3.543

2.008 2.402 2.795 3.189 3.583

2.017 2.441 2.835 3.228 3.622

2.087 2.480 2.847 3.268 3.661

2.126 2.520 2.913 3.307 3.701

5 0.197 0.591 0.984 1.378 1.772 (C) 2.165 2.559 2.953 3.346 3.740

6 0.236 0.630 1.024 1.417 1.811

1 mm = 0.03937 in 7 8 9 0.276 0.315 0.354 0.669 0.709 0.748 1.063 1.102 1.142 1.457 1.496 1.536 1.850 1.890 1.929

2.205 2.598 2.992 3.386 3.780

2.244 2.638 3.032 3.425 3.819

2.283 2.677 3.071 3.465 3.858

2.323 2.717 3.110 3.504 3.898

114E-5 SERIES

00 Index and foreword Foreword, safety and general information

Millimeters to inches

0 10 20 30 40 50 60 70 80 90

0 0 0.394 0.787 1.181 1.575 1.969 2.362 2.756 3.150 3.543

2 0.079 0.472 0.866 1.260 1.654 2.047 2.441 2.835 3.228 3.622

3 0.118 0.512 0.906 1.299 1.693 2.087 2.480 2.847 3.268 3.661

4 0.157 0.551 0.945 1.339 1.732 2.126 2.520 2.913 3.307 3.701

5 0.197 0.591 0.984 1.378 1.772 2.165 2.559 2.953 3.346 3.740

6 0.236 0.630 1.024 1.417 1.811 2.205 2.598 2.992 3.386 3.780

7 0.276 0.669 1.063 1.457 1.850 2.244 2.638 3.032 3.425 3.819

1 mm = 0.03937 in 8 9 0.315 0.354 0.709 0.748 1.102 1.142 1.496 1.536 1.890 1.929 2.283 2.323 2.677 2.717 3.071 3.110 3.465 3.504 3.858 3.898

1 2.20 24.25 46.30 68.34 90.39 112.44 134.48 156.53 178.57 200.62

2 4.41 26.46 48.50 70.55 92.59 114.64 136.69 158.73 180.78 202.83

3 6.61 28.66 50.71 72.75 94.80 116.85 138.89 160.94 182.98 205.03

4 8.82 30.86 51.91 74.96 97.00 119.05 141.10 163.14 185.19 207.24

5 11.02 33.07 55.12 77.16 99.21 121.25 143.30 165.35 187.39 209.44

6 13.23 35.27 57.32 79.37 101.41 123.46 145.51 167.55 189.60 211.64

7 15.43 37.48 59.53 81.57 103.62 125.66 147.71 169.76 191.80 213.85

1 kg = 2.2046 lb 8 9 17.64 19.84 39.68 41.89 61.73 63.93 83.78 85.98 105.82 108.03 127.87 130.07 149.91 152.12 171.96 174.17 194.01 196.21 216.05 218.26

1 0.264 2.906 5.548 8.189 10.831 13.473 16.115 18.756 21.398 24.040

2 0.528 3.170 5.812 8.454 11.095 13.737 16.379 19.020 21.662 24.304

3 0.793 3.434 6.076 8.718 11.359 14.001 16.643 19.285 21.926 24.568

4 1.057 3.698 6.340 8.982 11.624 14.265 16.907 19.549 22.190 24.832

5 1.321 3.963 6.604 9.246 11.888 14.529 17.171 19.813 22.455 25.096

6 1.585 4.227 6.869 9.510 12.152 14.795 17.435 20.077 22.719 25.361

1 l = 0.2642 U.S.Gal 7 8 9 1.849 2.113 2.378 4.491 4.755 5.019 7.133 7.397 7.661 9.774 10.039 10.303 12.416 12.680 12.944 15.058 15.322 15.586 17.700 17.964 18.228 20.341 20.605 20.870 22.983 23.247 23.511 25.625 25.889 26.153

1 0.039 0.433 0.827 1.220 1.614 2.008 2.402 2.795 3.189 3.583

Kilograms to pounds

0 10 20 30 40 50 60 70 80 90

0 0 22.05 44.09 66.14 88.18 110.23 132.28 154.32 176.37 198.42

l to U.S. Gallons

0 10 20 30 40 50 60 70 80 90

0 0 2.642 5.283 7.925 10.567 13.209 15.850 18.492 21.134 23.775

114E-5 SERIES

00-51

00 Index and foreword Foreword, safety and general information

l to U.K. Gallons

0 10 20 30 40 50 60 70 80 90

0 0 2.200 4.399 6.599 8.799 10.998 13.198 15.398 17.598 19.797

1 0.220 2.420 4.619 6.819 9.019 11.281 13.418 15.618 17.818 20.017

2 0.440 2.640 4.839 7.039 9.239 11.438 13.638 15.838 18.037 20.237

3 0.660 2.860 5.059 7.259 9.459 11.658 13.858 16.058 18.257 20.457

4 0.880 3.080 5.279 7.479 9.679 11.878 14.078 16.278 18.477 20.677

5 1.100 3.300 5.499 7.699 9.899 12.098 14.298 16.498 18.697 20.897

6 1.320 3.520 5.719 7.919 10.119 12.318 14.518 16.718 18.917 21.117

1 l = 0.21997 U.K.Gal 7 8 9 1.540 1.760 1.980 3.740 3.950 4.179 5.939 6.159 6.379 8.139 8.359 8.579 10.339 10.559 10.778 12.528 12.758 12.978 14.738 14.958 15.178 16.938 17.158 17.378 19.137 19.357 19.577 21.337 21.557 21.777

1 7.2 79.6 151.9 224.2 296.6 368.9 441.2 513.5 585.9 658.2 730.5 802.9 875.2 947.5 1019.9 1092.2 1164.5 1236.8 1309.2 1381.5

2 14.5 86.8 159.1 231.5 303.8 376.1 448.5 520.8 593.1 665.4 737.8 810.1 882.4 954.8 1027.1 1099.4 1171.7 1244.1 1316.4 1388.7

3 21.7 94.0 166.4 238.7 311.0 383.4 455.7 528.0 600.3 672.7 745.0 817.3 889.7 962.0 1034.3 1106.6 1179.0 1251.3 1323.6 1396.0

4 28.9 101.3 173.6 245.9 318.3 390.6 462.9 535.2 607.6 679.9 752.2 824.6 896.9 969.2 1041.5 1113.9 1186.2 1258.5 1330.9 1403.2

5 36.2 108.5 180.8 253.2 325.5 397.8 470.2 542.5 614.8 687.1 759.5 831.8 904.1 976.5 1048.8 1121.1 1193.4 1265.8 1338.1 1410.4

6 43.4 115.7 188.1 260.4 332.7 405.1 477.4 549.7 622.0 694.4 766.7 839.0 911.4 983.7 1056.0 1128.3 1200.7 1273.0 1345.3 1417.7

7 50.6 123.0 195.3 267.6 340.0 412.3 484.6 556.9 629.3 701.6 773.9 846.3 918.6 990.9 1063.2 1135.6 1207.9 1280.1 1352.6 1424.9

kgm to ft.lb

0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190

00-52

0 0 72.3 144.7 217.0 289.3 361.7 434.0 506.3 578.6 651.0 723.3 795.6 868.0 940.3 1012.6 1084.9 1157.3 1129.6 1301.9 1374.3

1 kgm = 7.233 ft.lb 8 9 57.9 65.1 130.2 137.4 202.5 209.8 274.9 282.1 347.2 354.4 419.5 426.8 491.8 499.1 564.2 571.4 636.5 643.7 708.8 716.1 781.2 788.4 853.5 860.7 925.8 933.1 998.2 1005.4 1070.5 1077.7 1142.8 1150.0 1215.1 1222.4 1287.5 1294.7 1359.8 1367.0 1432.1 1439.4

114E-5 SERIES

00 Index and foreword Foreword, safety and general information

kg/cm2 to lb/in22

0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240

0 0 142.2 284.5 426.7 568.9 711.2 853.4 995.6 1,138 1,280 1,422 1,565 1,707 1,849 1,991 2,134 2,276 2,418 2,560 2,702 2,845 2,987 3,129 3,271 3,414

114E-5 SERIES

1 14.2 156.5 298.7 440.9 583.2 725.4 867.6 1,010 1,152 1,294 1,437 1,579 1,721 1,863 2,005 2,148 2,290 2,432 2,574 2,717 2,859 3,001 3,143 3,286 3,428

2 28.4 170.7 312.9 455.1 597.4 739.6 881.8 1,024 1,166 1,309 1,451 1,593 1,735 1,877 2,020 2,162 2,304 2,446 2,589 2,731 2,873 3,015 3,158 3,300 3,442

3 42.7 184.9 327.1 469.4 611.6 753.8 896.1 1,038 1,181 1,323 1,465 1,607 1,749 1,892 2,034 2,176 2,318 2,460 2,603 2,745 2,887 3,030 3,172 3,314 3,456

4 56.9 199.1 341.4 483.6 625.8 768.1 910.3 1,053 1,195 1,337 1,479 1,621 1,764 1,906 2,048 2,190 2,333 2,475 2,617 2,759 2,901 3,044 3,186 3,328 3,470

5 71.1 213.4 355.6 497.8 640.1 782.3 924.5 1,067 1,209 1,351 1,493 1,636 1,778 1,920 2,062 2,205 2,347 2,489 2,631 2,773 2,916 3,058 3,200 3,343 3,485

6 85.3 227.6 369.8 512.0 654.3 796.5 938.7 1,081 1,223 1,365 1,508 1,650 1,792 1,934 2,077 2,219 2,361 2,503 2,646 2,788 2,930 3,072 3,214 3,357 3,499

1 kg/cm2 = 14.2233 lb/in22 7 8 9 99.6 113.8 128.0 241.8 256.0 270.2 384.0 398.3 412.5 526.3 540.5 554.7 668.5 682.7 696.9 810.7 825.0 839.2 953.0 967.2 981.4 1,095 1,109 1,124 1,237 1,252 1,266 1,380 1,394 1,408 1,522 1,536 1,550 1,664 1,678 1,693 1,806 1,821 1,835 1,949 1,963 1,977 2,091 2,105 2,119 2,233 2,247 2,262 2,375 2,389 2,404 2,518 2,532 2,546 2,660 2,674 2,688 2,802 2,816 2,830 2,944 2,958 2,973 3,086 3,101 3,115 3,229 3,243 3,257 3,371 3,385 3,399 3,513 3,527 3,542

00-53

00 Index and foreword Foreword, safety and general information

Temperature Conversion of Fahrenheit to Celsius • A simple way to convert a Fahrenheit temperature reading into a Celsius temperature reading or vice versa is to see the number in the center column of the following table. The figures on the following table show the temperatures in both Fahrenheit and Celsius.

• When converting from Fahrenheit to Celsius degrees, consider the center column to be a table of Fahrenheit temperatures and read the corresponding Celsius temperature in the column at the left.

• When converting from Celsius to Fahrenheit degrees, consider the center column to be a table of Celsius values, and read the corresponding Fahrenheit temperature on the right. °C -40.4 -37.2 -34.4 -31.7 -28.9 -28.3 -27.8 -27.2 -26.7 -26.1 -25.6 -25.0 -24.4 -23.9 -23.3 -22.8 -22.2 -21.7 -21.1 -20.6 -20.0 -19.4 -18.9 -18.3 -17.8 -17.2 -16.7 -16.1 -15.6 -15.0 -14.4 -13.9 -13.3 -12.8 -12.2

00-54

-40 -35 -30 -25 -20 -19 -18 -17 -16 -15 -14 -13 -12 -11 -10 -9 -8 -7 -6 -5 -4 -3 -2 -1 0 1 2 3 4 5 6 7 8 9 10

°F -40.0 -31.0 -22.0 -13.0 -4.0 -2.2 -0.4 1.4 3.2 5.0 6.8 8.6 10.4 12.2 14.0 15.8 17.6 19.4 21.2 23.0 24.8 26.6 28.4 30.2 32.0 33.8 35.6 37.4 39.2 41.0 42.8 44.6 46.4 48.2 50.0

°C -11.7 -11.1 -10.6 -10.0 -9.4 -8.9 -8.3 -7.8 -7.2 -6.7 -6.1 -5.6 -5.0 -4.4 -3.9 -3.3 -2.8 -2.2 -1.7 -1.1 -0.6 0 0.6 1.1 1.7 2.2 2.8 3.3 3.9 4.4 5.0 5.6 6.1 6.7 7.2

11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45

°F 51.8 53.6 55.4 57.2 59.0 60.8 62.6 64.4 66.2 68.0 69.8 71.6 73.4 75.2 77.0 78.8 80.6 82.4 84.2 86.0 87.8 89.6 91.4 93.2 95.0 96.8 98.6 100.4 102.2 104.0 105.8 107.6 109.4 111.2 113.0

°C 7.8 8.3 8.9 9.4 10.0 10.6 11.1 11.7 12.2 12.8 13.3 13.9 14.4 15.0 15.6 16.1 16.7 17.2 17.8 18.3 18.9 19.4 20.0 20.6 21.1 21.7 22.2 22.8 23.3 23.9 24.4 25.0 25.6 26.1 26.7

46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80

°F 114.8 116.6 118.4 120.2 122.0 123.8 125.6 127.4 129.2 131.0 132.8 134.6 136.4 138.2 140.0 141.8 143.6 145.4 147.2 149.0 150.8 152.6 154.4 156.2 158.0 159.8 161.6 163.4 165.2 167.0 168.8 170.6 172.4 174.2 176.0

°C 27.2 27.8 28.3 28.9 29.4 30.0 30.6 31.1 31.7 32.2 32.8 33.3 33.9 34.4 35.0 35.6 36.1 36.7 37.2 37.8 40.6 43.3 46.1 48.9 51.7 54.4 57.2 60.0 62.7 65.6 68.3 71.1 73.9 76.7 79.4

1°C = 33.8°F °F 81 177.8 82 179.6 83 181.4 84 183.2 85 185.0 86 186.8 87 188.6 88 190.4 89 192.2 90 194.0 91 195.8 92 197.6 93 199.4 94 201.2 95 203.0 96 204.8 97 206.6 98 208.4 99 210.2 100 212.0 105 221.0 110 230.0 115 239.0 120 248.0 125 257.0 130 266.0 135 275.0 140 284.0 145 293.0 150 302.0 155 311.0 160 320.0 165 329.0 170 338.0 175 347.0

114E-5 SERIES

SHOP MANUAL

ENGINE 114E–5 SERIES Model

Serial Number

114E–5 SERIES

01 Specification 2 01 Specification

114E-5 SERIES

01-1

01 Specification Table of contents

Table of contents

(ALL-0310-002-A-00-A)

01 Specification................................................................................................................................. 01-1 Table of contents ........................................................................................................................ 01-2 General information .................................................................................................................... 01-3 Exhaust gas regulation ......................................................................................................... 01-3 Specifications............................................................................................................................. 01-6 Applicable machines ............................................................................................................ 01-6 Specifications ...................................................................................................................... 01-7 General view ..................................................................................................................... 01-10 Engine performance curve .................................................................................................... 01-6

01-2

114E-5 SERIES

01 Specification Exhaust gas regulation

General information

(ALL-0000-001-A-00-A)

Exhaust gas regulation

(ENG-A000-017-K-00-A)

• The 3 main diesel engine emissions that adversely impact the human body and the environment are the following: 1. NOx (nitrogen oxides): causes breathing problems and acid rain 2. HC (hydrocarbons): causes photochemical smog 3. PM (particulates in air such as soot): causes cancer and breathing problems • NOx are produced when the nitrogen (N2) in air reacts with oxygen (O2) at high temperatures. These substances are produced when a diesel engine combustion takes place with too much air (nitrogen). To reduce NOx, it is necessary to lower the combustion temperature in the cylinder to suppress the oxidation of N (nitrogen). Therefore, an air-cooled aftercooler (2) is used for lowering the temperature of the air from turbocharger (1).

• HC is the main component of fuel. HC in the blowby gas holds the most part of hazardous materials emitted from a diesel engine, however, this has been released into the air.

• Incomplete combustion produces HC and also PM, which are solid particles adhering to soot, etc.

Generally, there is a antinomy relation between NOx and PM (trying to reduce either results in increase of the other). To reduce PM, combustion has been improved by using common rail (3), microparticulating the fuel spray by using an electronically controlled high-pressure fuel injection system, reducing the injection period, and optimizing the injection timing.

• Emission regulations are established in Japan, US, and various regions in Europe. The history of the USA regulations from the 1st (Tier 1) to 4th (Tier 4) is traced in the following table. (Transition of USA EPA(*1) emission regulations, for engine rated horsepowers 130 kW to 560 kW) The horizontal axis shows the NOx + NMHC(*2) level, and the vertical axis shows the PM level. In the 4th (Tier 4) regulation, both the NOx + NMHC and PM standards are tightened to levels approx. 1/7 of the 3rd (Tier 3) regulation. This 4th regulation is referred to as "Tier 4 regulation"(*3). *1: United States Environmental Protection Agency *2: General term for hydrocarbons (HC) that have a high photochemical reactivity. *3: There are 2 stages in Tier 4. The 1st stage is referred to as "Tier 4 Interim", for which actions are taken this time. The 2nd stage is referred to as "Tier 4 Final".

114E-5 SERIES

01-3

01 Specification Exhaust gas regulation

Actions taken to meet the Tier 4 regulation

(ENG114-A000-018-K-00-A)

1. Engine 2. Air cleaner 3. Air-cooled aftercooler 4. EGR cooler dP: KDPF differential pressure and outlet pressure sensor ECU (CM2250): Engine controller EGRSOL: EPC valve (for EGR) EGRV: EGR valve

01-4

114E-5 SERIES

01 Specification Exhaust gas regulation

MAF: Mass air flow and temperature sensor PAMB: Ambient pressure sensor PCCV: Crankcase pressure sensor PEX: Exhaust manifold pressure sensor PIM: Intake manifold pressure sensor REV: Turbocharger speed sensor SEGR: EGR valve lift sensor SVGT: KVGT position sensor T: Temperature sensor in KDPF T1: EGR orifice temperature sensor TIM: Intake manifold temperature sensor VGTSOL: EPC valve (for KVGT) • Tier4 is improved mainly over Tier3 in the following points.

1. Employment of EGR (Exhaust Gas Recirculation) cooler (4) (reduction of NOx) 2. Increase of intake air quantity in low engine speed range by changing turbocharger (KVGT) speed (reduction of PM) 3. Oxygen concentration control by EGR ratio control corresponding to operating condition attained by employing high-precision EGR valve (EGRV), mass air flow and temperature sensor (MAF), and engine controller (CM2250), and by sensing condition of each part of EGR circuit (reduction of NOx and PM) 4. Fine spraying of injected fuel by increasing common rail pressure and fuel injection pressure (reduction of PM) 5. Internal circulation of blowby gas by employing blowby reductor (KCCV) (reduction of HC) 6. Employment of soot-capturing filter (KCSF) (reduction of PM) 7. Employment of oxidation catalyzer (KDOC) (reduction of NOx) 8. Control of characteristic dispersion of injectors with engine controller (CM2250) 9. Improvement of combustion chamber (reduction of NOx, PM, and fuel consumption) 10. Automatic control of fuel injection and turbocharger (KVGT) by recognizing high altitude with ambient pressure sensor (PAMB) (reduction of NOx and PM at high altitude) 11. Speed (REV) detection of turbocharger (KVGT) (Protection of KGVT) 12. When clogging of the soot-capturing filter (KCSF) is detected with KDPF delta pressure (dp), engine controller (CM2250) performs regeneration (*) process (automatic regeneration) as needed, or the need of manual regeneration is displayed on machine monitor (for maintaining of KDPF function). *: This is a new function used for purifying (oxidizing) soot accumulated in the soot-capturing filter (KCSF) inside the KDPF. • HB335–1, HB335LC-1, HB365–1, and HB365LC-1 are applicable toTier3 standards, and the following functions are not equipped.

1. Blowby reductor (KCCV) 2. KDPF related functions (KCSF, KDOC)

114E-5 SERIES

01-5

01 Specification Applicable machines

Specifications

(ALL-2111-001-A-00-A)

Applicable machines Engine

(ENG114-A000-00V-K-00-A)

Engine serial No.

Machine model D65EX-17 D65PX-17 D65WX-17

SAA6D114E-5

01-6

PC360LC-10 HB335–1 HB335LC–1 HB365–1 HB365LC–1

Bulldozer Hydraulic excavator Hybrid hydraulic excavator

114E-5 SERIES

01 Specification Specifications

Specifications

(ENG107-2110-001-A-00-A)

Applicable machines: D65EX-17, D65PX-17, D65WX-17 Engine model No. of cylinders–bore x stroke Piston displacement Firing order Overall length Overall width Overall height (excluding exhaust Dimensions pipe) Overall height (including exhaust pipe) Rated horsepower (Gross) Max. torque (Gross) Max. speed with no load (High idle speed) Min. speed with no load (Low idle speed) Fuel consumption ratio at rated horsepower Dry weight (excluding KDPF) Fuel injection system Fuel injection system control Lubricating oil amount (Refill capacity) Coolant amount Alternator Starting motor KVGT (Turbocharger)

Performance

114E-5 SERIES

mm l {cc} – mm mm

SAA6D114E-5 6 –114 x 144.5 8.85 {8,850} 1-5-3-6-2-4 1,215 950

mm

1,615

mm

–

kW {HP}/ min–1 {rpm} Nm {kgm}/ min–1 {rpm}

(ENG114-2110-030-A-00-A)

163.7 {219} / 1,950 {1,950} 1,050 {107.1} / 1,450 {1,450}

min–1 {rpm}

2,100 ± 50 {2,100 ± 50}

min–1 {rpm}

825 ± 25 {825 ± 25}

g/kWh {g/HPh} 227 {169} kg – – l l – – –

996 High-pressure common rail type Electronic control type 30 (25) 12.8 24V, 60A, 90A (if equipped) 24V, 7.5kW, 11kW (if equipped) HOLSET HE431Vh

01-7

01 Specification Specifications

Applicable machines: PC360LC-10

(ENG114-2110-030-A-01-A)

Engine model No. of cylinders–bore x stroke Piston displacement Firing order Overall length Overall width Overall height (excluding exhaust Dimensions pipe) Overall height (including exhaust pipe) Rated horsepower (Gross) Max. torque (Gross) Max. speed with no load (High idle speed) Min. speed with no load (Low idle speed) Fuel consumption ratio at rated horsepower Dry weight (excluding KDPF) Fuel injection system Fuel injection system control Lubricating oil amount (Refill capacity) Coolant amount Alternator Starting motor KVGT (Turbocharger)

Performance

01-8

mm l {cc} – mm mm

SAA6D114E-5 6 –114 x 144.5 8.85 {8,850} 1-5-3-6-2-4 1,624 981

mm

–

mm

1,530

kW {HP}/ min–1 {rpm} Nm {kgm}/ min–1 {rpm}

202 {271}/ 1,950 {1,950} 1,171 {119} / 1,450 {1,450}

min–1 {rpm}

2,050 ± 30 {2,050 ± 30}

min–1 {rpm}

1,000 ± 25 {1,000 ± 25}

g/kWh {g/HPh} 216 {161} kg – – l l – – –

865 High-pressure common rail type Electronic control type 35 (30) 12.7 24 V, 60 A 24 V, 11 kW HOLSET HE431Vh

114E-5 SERIES

01 Specification Specifications

Applicable machines: HB335-1, HB335LC-1, HB365-1, HB365LC-1

(ENG114-2110-030-A-

04-A)

Engine model No. of cylinders–bore x stroke Piston displacement Firing order Overall length Overall width Overall height (excluding exhaust Dimensions pipe) Overall height (including exhaust pipe) Rated horsepower (Gross) Max. torque (Gross) Performance

Max. speed with no load (High idle speed) Min. speed with no load (Low idle speed) Fuel consumption ratio at rated horsepower

mm l {cc} – mm mm

SAA6D114E-5 6 –114 x 144.5 8.85 {8,850} 1-5-3-6-2-4 1,614 993

mm

–

mm

1,625

kW {HP}/ min–1 {rpm} Nm {kgm}/ min–1 {rpm}

202 {271}/ 1,950 {1,950} 1,171 {119} / 1,450 {1,450}

min–1 {rpm}

2,050 ± 30 {2,050 ± 30}

min–1 {rpm}

700 ± 25 {700 ± 25}

g/kWh {g/HPh} 216 {161}

Dry weight Fuel injection system Fuel injection system control Lubricating oil amount (Refill capacity) Coolant amount

kg – – l l

850 High-pressure common rail type Electronic control type 40 (38) 12.7

Alternator

–

24 V, 60 A

Starting motor KVGT (Turbocharger)

– –

24V, 7.5kW, 11kW (if equipped) HOLSET HE431Vh

114E-5 SERIES

01-9

01 Specification General view

General view

(ENG107-2180-001-A-00-A)

Applicable machines: D65EX-17, D65PX-17, D65WX-17

(ENG114-2180-041-A-00-A)

Left side a The shape is subject to machine models.

1. Center of crankshaft 2. Rear face of flywheel housing

01-10

114E-5 SERIES

01 Specification General view

Right side a The shape is subject to machine models.

1. Center of crankshaft 2. Rear face of flywheel housing

114E-5 SERIES

01-11

01 Specification General view

Front side a The shape is subject to machine models.

1. Center of crankshaft 2. Cylinder center

01-12

114E-5 SERIES

01 Specification General view

Back side a The shape is subject to machine models.

1. Center of crankshaft 2. Cylinder center

114E-5 SERIES

01-13

01 Specification General view

Applicable machines: PC360LC-10

(ENG114-2180-041-A-01-A)

Left side a The shape is subject to machine models.

1. Center of crankshaft 2. Rear face of flywheel housing

01-14

114E-5 SERIES

01 Specification General view

Right side a The shape is subject to machine models.

1. Center of crankshaft 2. Rear face of flywheel housing

114E-5 SERIES

01-15

01 Specification General view

Front side a The shape is subject to machine models.

1. Center of crankshaft 2. Cylinder center

01-16

114E-5 SERIES

01 Specification General view

Back side a The shape is subject to machine models.

1. Center of crankshaft 2. Cylinder center

114E-5 SERIES

01-17

01 Specification General view

Applicable machines: HB335-1, HB335LC-1, HB365-1, HB365LC-1

(ENG114-2180-041-A-

04-A)

Left side a The shape is subject to machine models.

1. Center of crankshaft 2. Rear flange back side

114E-5 SERIES

01-1

01 Specification General view

Right side a The shape is subject to machine models.

1. Center of crankshaft 2. Rear flange back side

01-2

114E-5 SERIES

01 Specification General view

Front side a The shape is subject to machine models.

1. Center of crankshaft 2. Center of cylinder

114E-5 SERIES

01-3

01 Specification General view

Rear side a The shape is subject to machine models.

1. Center of crankshaft 2. Center of cylinder

01-4

114E-5 SERIES

01 Specification General view

Dimensions table

(ENG114-2110-2A4-A-00-A)

a These dimensions are given for reference when the engine is set on a test bench.

Unit: mm Engine

SAA6D114E-5

114E-5 SERIES

Machine model D65EX-17 D65PX-17 D65WX-17 PC360LC-10 HB335–1 HB335LC–1 HB365–1 HB365LC–1

A

Dimension of each part B C

D

1,215.1

1,614.6

396.9

949.8

1,647

1,530

444

981

1,614

1,625

500

993

01-5

01 Specification Engine performance curve

Engine performance curve

(ENG107-2170-001-A-01-A)

Applicable machines: D65EX-17, D65PX-17, D65WX-17

(ENG114-2170-34E-A-00-A)

Rated horsepower: 163.7 kW {219 HP}/1,950 rpm (Gross) Max. torque: 1,050 Nm {107.1 kgm}/1,450 rpm (Gross)

01-6

114E-5 SERIES

01 Specification Engine performance curve

Applicable machines: PC360LC-10

(ENG114-2170-34E-A-01-A)

Rated horsepower: 202kW {271 HP}/1,950 rpm (Gross) Max. torque: 1,171 Nm {119 kgm}/1,450 rpm (Gross)

114E-5 SERIES

01-7

01 Specification Engine performance curve

Applicable machines: HB335-1, HB335LC-1, HB365-1, HB365LC-1

(ENG114-2170-34E-A-

04-A)

Rated horsepower: 202 kW {271 HP} / 1,950 min–1 {1,950 rpm}(Gross) Max. torque: 1.171 Nm {119 kgm} / 1,450 min–1 {1,450rpm}(Gross)

01-8

114E-5 SERIES

SHOP MANUAL

ENGINE 114E–5 SERIES Model

Serial Number

114E–5 SERIES

10 Structure and function 3 10 Structure and function

114E-5 SERIES

10-1

10 Structure and function Table of contents

Table of contents

(ALL-0310-002-A-00-A)

10 Structure and function ................................................................................................................... 10-1 Table of contents ........................................................................................................................ 10-2 Components layout..................................................................................................................... 10-3 Components layout drawing.................................................................................................. 10-3 Intake and exhaust system parts .................................................................................................. 10-5 Intake and exhaust system layout drawing ............................................................................. 10-5 Intake and exhaust system circuit diagram ............................................................................. 10-6 Air cleaner ........................................................................................................................... 10-8 KVGT.................................................................................................................................. 10-9 Aftercooler......................................................................................................................... 10-16 EGR system piping drawing ................................................................................................ 10-17 EGR system circuit diagram ................................................................................................ 10-19 EGR valve......................................................................................................................... 10-21 EGR cooler........................................................................................................................ 10-23 KCCV layout drawing ......................................................................................................... 10-25 KCCV ventilator ................................................................................................................. 10-28 KDPF................................................................................................................................ 10-32 Engine main body parts............................................................................................................. 10-36 Cylinder head .................................................................................................................... 10-36 Cylinder block .................................................................................................................... 10-38 Main moving parts.............................................................................................................. 10-40 Vibration damper................................................................................................................ 10-43 Timing gear ....................................................................................................................... 10-44 Front cover ........................................................................................................................ 10-45 Valve system ..................................................................................................................... 10-46 Flywheel............................................................................................................................ 10-47 Lubrication system.................................................................................................................... 10-48 Lubrication system parts layout drawing ............................................................................... 10-48 Lubrication system circuit diagram ....................................................................................... 10-50 Oil pump ........................................................................................................................... 10-51 Boost oil pump ................................................................................................................... 10-52 Oil filter.............................................................................................................................. 10-53 Oil cooler........................................................................................................................... 10-54 Regulator valve.................................................................................................................. 10-55 Safety valve....................................................................................................................... 10-56 Oil pan .............................................................................................................................. 10-57 Fuel system ............................................................................................................................. 10-58 Fuel system parts layout drawing......................................................................................... 10-58 Fuel system circuit diagram................................................................................................. 10-60 Supply pump ..................................................................................................................... 10-64 Pre-filter ............................................................................................................................ 10-68 Main filter .......................................................................................................................... 10-69 Cooling system......................................................................................................................... 10-70 Cooling system parts layout drawing.................................................................................... 10-70 Cooling system circuit diagram............................................................................................ 10-71 Drive pulley ....................................................................................................................... 10-73 Water pump....................................................................................................................... 10-77 Thermostat ........................................................................................................................ 10-78 Electrical equipment.................................................................................................................. 10-80 Alternator .......................................................................................................................... 10-80 Starting motor .................................................................................................................... 10-84 Intake air heater ................................................................................................................. 10-88 Engine wiring harness ........................................................................................................ 10-89 Engine controller ................................................................................................................ 10-91 Sensor .............................................................................................................................. 10-97

10-2

114E-5 SERIES

10 Structure and function Components layout drawing

Components layout

(ALL-A000-001-K-04-A)

Components layout drawing

(ENG114-A000-04D-K-00-A)

a The D65EX–17 is shown as an example. The shape is subject to machine models.

1. Starting motor 2. EGR cooler 3. Engine oil filter 4. KDPF 5. KCCV ventilator 114E-5 SERIES

10-3

10 Structure and function Components layout drawing

6. Alternator 7. Vibration damper and crankshaft pulley 8. Auto-tensioner 9. Air cleaner 10. KVGT 11. Supply pump 12. Boost oil pump 13. Engine controller 14. Oil pan 15. Oil cooler

10-4

114E-5 SERIES

10 Structure and function Intake and exhaust system layout drawing

Intake and exhaust system parts

(ENG107-A900-001-K-00-A)

Intake and exhaust system layout drawing

(ENG114-A900-04D-K-00-A)

a The D65EX–17 is shown as an example. The shape is subject to machine models.

1. KVGT 2. EGR valve 3. Air intake connector 4. Exhaust manifold 5. EGR cooler A: To KDPF B: From EGR valve C: From aftercooler D: To intake manifold E: From air cleaner F: To aftercooler G: From exhaust manifold

114E-5 SERIES

10-5

10 Structure and function Intake and exhaust system circuit diagram

Intake and exhaust system circuit diagram

(ENG114-A900-052-K-00-A)

1. Air cleaner 2. KVGT 3. Air cooled aftercooler 4. Intake air heater 5. Intake manifold 6. Exhaust manifold 7. EGR valve 8. KCCV ventilator 9. KDPF 10. EGR cooler 11. Breather 12. Engine oil pan 13. Engine A: From atmosphere B: To atmosphere C: To oil pan

10-6

114E-5 SERIES

10 Structure and function Intake and exhaust system circuit diagram

Function

(ENG107-A900-042-K-00-A)

• A variable displacement turbocharger KVGT (KOMATSU Variable Geometry Turbocharger), EGR system (EGR valve and EGR cooler) which sends a part of exhaust gas back to the combustion chamber in order to suppress generation of NOx, KDPF (KOMATSU Diesel Particulate Filter) which purify the exhaust gas, and a blowby gas recirculation system KCCV (KOMATSU Closed Crankcase Ventilation) are introduced for this engine.

• Clean air is necessary to maintain the engine performance. If dirt or dust enters, the engine can get damaged and the performance may be degraded.

• Air flows through air cleaner (1), KVGT (2), and air cooled aftercooler (3) into the engine.

• The KVGT has a variable geometry mechanism not found in conventional turbochargers. The KVGT can get seriously damaged if foreign material enters the KVGT. Therefore, a high quality air cleaner is essential for the engine. Follow the procedures in the Operation and Maintenance Manual to clean or replace the air cleaner element, and be careful not to let foreign material enter the system during replacement work.

• Intake air flows from air cleaner (1) into the compressor side of KVGT (2). The air charged at KVGT (2) is cooled at air cooled aftercooler (3). The air then flows through air intake manifold (5) and then into the cylinders for combustion.

• Exhaust gas is sent from exhaust manifold (6) to the turbine side of KVGT (2). Thus the turbine impeller is driven by the energy of the exhaust gas.

• The engine controller outputs signals to the EGR system for opening EGR valve (7) most properly according to the load on the engine to attain both clean exhaust gas and low fuel consumption.

• When EGR valve (7) opens, a part of the exhaust gas (EGR gas) flows from exhaust manifold (6) through EGR piping to the EGR cooler.

• The exhaust gas cooled by EGR cooler (10) flows through EGR valve (7) and mixes with the intake air and then flows in the intake manifold (5).

• KDPF (9) features a newly designed mechanism and is installed to meet the new exhaust gas regulations.

The KDPF consists of KDOC (oxidation catalyzer) and KCSF (soot collecting filter).

• Particulate soot in the exhaust gas are collected to purify the exhaust gas.

114E-5 SERIES

10-7

10 Structure and function Air cleaner

Air cleaner

(ENG114-A910-041-K-00-A)

a The D65EX–17 is shown as an example. The shape is subject to machine models.

1. Vacuator valve 2. Inlet 3. Air cleaner clogging sensor or dust indicator mounting 4. Outlet 5. Mass air flow, temperature sensor mounting 6. Rectifier wire net 7. Outer element 8. Inner element

Specifications

(ENG114-A910-030-K-00-A)

• Type: Cyclone pack type • Filtering area (outer element): 9.94 m2 • Filtering area (inner element): 1.33 m2

Operation

(ENG107-A910-044-K-00-A)

• Since inlet (2) is set in the tangential direction, air is given sufficient centrifugal force by the simple spiral guide vanes (8), not by guide plates.

• Air containing dust is sucked in vertically through inlet (2) and the dust is separated by the centrifugal effect by guide vane (8).

• More than 99.9% of the dust is removed by outer element (7) and clean air is sucked in the engine through inner element (9) and outlet (4).

• The dust and water separated by guide vane (8) swirl along the inside wall of body and enter vacuator valve (1) and then are discharged out automatically.

• Rectifier wire net (6) rectifies the air flow to the mass air flow and temperature sensor which is important to the engine control.

10-8

114E-5 SERIES

10 Structure and function KVGT

KVGT

(ENG114-AA10-041-K-00-A)

KVGT: Abbreviation for KOMATSU Variable Geometry Turbocharger and it is variable displacement turbocharger. a The shape is subject to machine models.

114E-5 SERIES

10-9

10 Structure and function KVGT

1. Blower housing 2. KVGT speed sensor 3. Hydraulic actuator 4. Turbine housing 5. Plate 6. Vane 7. Nozzle ring 8. Push rod 9. Shaft 10. Blower impeller 11. Turbine impeller 12. Piston A: Air intake inlet B: Air intake outlet C: Exhaust inlet D: Exhaust outlet

Operation

(ENG114-AA10-044-K-00-A)

1. Air cleaner 2. KVGT 3. KDPF 4. EGR cooler 5. EGR valve C: Blower impeller T: Turbine impeller • The new exhaust gas regulation not only requires to control emissions at high engine speeds but also at low engine speeds. To meet the requirements, the EGR ratio is increased. (EGR ratio = volume of EGR/ intake air flow) • To obtain a high EGR ratio especially at low engine speeds, the turbine inlet pressure (P3) must be higher than the boost pressure (P2). A variable displacement turbocharger (KVGT), in which the exhaust gas pressure hitting the turbine impeller (T) can be adjusted, is introduced.

• The charged pressure rises faster, also contributing to suppress the generation of PM (particles) due to insufficient oxygen at low engine speeds.

• The turbine impeller (T) drives the blower impeller (C) via a shaft. In turn the blower impeller (C) sends a large amount of air to the cylinders for combustion. When the air flow from KVGT (2) increases, more fuel can be injected, and the engine output increases.

• Since the density of the air and the amount of oxygen increases when the air is cooled, more fuel can be injected, and the engine output increases.

10-10

114E-5 SERIES

10 Structure and function KVGT

a Adequate amount of clean high quality oil is required to maintain the KVGT performance. Be sure to use Komatsu genuine high quality oil. Follow the procedures in the Operation and Maintenance Manual when replacing oil or oil filter.

• Exhaust gas enters from (C) of turbine housing (4), flows through section (P) and out from (D). Section (P) is surrounded by plate (5) and nozzle ring (7) fixed on turbine housing (4), and vane (6).

• The passage area changes when push rod (8) slides right or left.

• The hydraulic actuator (3) moves piston (12) in the actuator up/down by using the oil pressure controlled at the EPC valve installed to the EGR valve, and also controls the right/left slide of push rod (8).

• Exhaust gas hits vane (6), and then turbine impeller (11) drives blower impeller (10) via shaft (9). This works as a compressor and the air entered from (A) is compressed and sent out from (B).

• When the exhaust gas pressure at the inlet (C) of turbine housing (4) is low (at low engine speeds), push rod (8) slides to the right to narrow section (P).

• Then the exhaust gas pressure to turbine impeller (11) increases, the turbocharger speed also increases, and more air (oxygen) is inhaled.

• The turbocharger speed is sensed by KVGT speed sensor (2).

When nozzle ring is closed • At low engine speeds, exhaust gas inlet passage (P) is narrowed (L1). (Not completely closed) • When the turbine inlet pressure increases while the nozzle ring is closed, the flow speed to the turbine increases and the turbocharger speed increases.

114E-5 SERIES

10-11

10 Structure and function KVGT

When nozzle ring is open • At high engine speeds, exhaust gas inlet passage (P) is widened (L2).

• As the engine speed and the turbine inlet pressure (exhaust gas pressure) increases, exhaust gas inlet passage (P) widens (L2) to effectively apply the exhaust gas pressure to turbine impeller (11).

a Nozzle ring (7), vane (6), and push rod (8) are integrated and slide together but do not rotate. a KVGT position sensor is installed to hydraulic actuator (3). The KVGT position sensor is calibrated together with the variable mechanism in the KVGT, and values are stored in the memory inside the KVGT position sensor. If any of the hydraulic actuator (3), KVGT position sensor, or KVGT body fails, replace the whole KVGT. Hydraulic actuator operation • Hydraulic actuator (6) is moved by the oil pressure controlled by EPC valve (8) installed to EGR valve (10).

• The force for the movement is the oil pressure supplied from boost oil pump (12). a The D65EX–17 is shown as an example. The shape is subject to machine models.

10-12

114E-5 SERIES

10 Structure and function KVGT

• Position of hydraulic actuator (6) is sensed by KVGT position sensor (5) and the signals are fed back to engine controller (7).

114E-5 SERIES

10-13

10 Structure and function KVGT

1. Air cleaner 2. Mass air flow and temperature sensor 3. KVGT 4. KVGT speed sensor 5. KVGT position sensor 6. Hydraulic actuator 7. Engine controller 8. EPC valve (for KVGT) 9. KDPF 10. EGR system (EGR cooler, EGR valve) 11. EGR orifice temperature sensor C: Blower impeller T: Turbine impeller KVGT control system • Based on information from KVGT position sensor (5), mass air flow and temperature sensor (2), and KVGT speed sensor (4), etc., the engine controller (7) moves hydraulic actuator (6) by using the oil pressure controlled by EPC valve (8), to move the piston.

• A good response at high altitudes is maintained by sensing high elevations with the ambient pressure sensor, and automatically controlling the fuel injection and the KVGT. • The KVGT is protected by controlling its speed to prevent overspeeds.

Lubrication • Cooled oil from the engine oil cooler is sent through the supply pipe to the KVGT for lubrication.

• Oil is sent to the bearing housing to lubricate the shaft bearing and thrust bearing.

• Return oil is drained from the return pipe connected to the bottom of the bearing housing and falls to the oil pan.

10-14

114E-5 SERIES

10 Structure and function KVGT

Cooling • Coolant from the cylinder block enters the center housing to cool the KVGT. • Coolant return flows from the center housing and joins the flow at the EGR cooler outlet piping, then flows through the water inlet connector to the water pump.

114E-5 SERIES

10-15

10 Structure and function Aftercooler

Aftercooler

(ENG114-A9A0-041-K-00-A)

a The D65EX–17 is shown as an example. The shape is subject to machine models.

1. Core 2. Tank 3. Tube 4. Fin A: Intake air outlet B: Intake air inlet

Specifications • • • •

(ENG114-A9A0-030-K-00-A)

Cooling method: Air-cooled type Core type: Rectangular aluminum wave fin Fin pitch: 8/2 ± 1 Total heat dissipation area: 15.89 m2

10-16

114E-5 SERIES

10 Structure and function EGR system piping drawing

EGR system piping drawing

(ENG114-A9J0-04D-K-00-A)

EGR: Abbreviation for Exhaust Gas Recirculation. a The D65EX-17 is shown as an example. The shape is subject to machine models.

1. KVGT 2. EGR valve 3. Air intake pipe 4. Air intake connector 5. Exhaust manifold 6. EGR cooler

114E-5 SERIES

10-17

10 Structure and function EGR system piping drawing

Function

(ENG107-A9J0-042-K-00-A)

• EGR valve (driven hydraulically) Controls the gas flow from the exhaust system to the air intake system. Since the exhaust pressure is higher than the boost pressure, the exhaust gas flows to the air intake side.

• EGR cooler Cools the exhaust gas.

Engine coolant is used for cooling.

• Air intake connector Returns the air from the air-cooled aftercooler and exhaust gas from the EGR valve to the air intake side.

• Each sensor Controls the EGR according to the operating condition.

Troubleshoots the system.

• Controls each part of the EGR circuit and controls the EGR rate according to the operating condition to ensure clean exhaust at all times.

• Since the EGR circuit is monitored and troubleshooted, a serious trouble is prevented.

10-18

114E-5 SERIES

10 Structure and function EGR system circuit diagram

EGR system circuit diagram

(ENG107-A9J0-052-K-00-A)

a EGR: Abbreviation for Exhaust Gas Recirculation

1. Air cleaner 2. KDPF 3. Ambient pressure sensor 4. Aftercooler 5. EGR orifice temperature sensor 6. EGR cooler 7. EGR valve 8. Hydraulic actuator (power piston) 9. EPC valve (for EGR valve) 10. EGR valve lift sensor 11. EPC valve (for KVGT) 12. Exhaust manifold 13. Boost oil pump 14. Air intake manifold 15. Charge (boost) pressure and temperature sensor 16. Engine controller C: Blower impeller T: Turbine impeller

Operation

(ENG107-A9J0-044-K-00-A)

• The engine controller outputs signals for opening EGR valve (7) most properly according to the load on the engine to attain both clean exhaust gas and low fuel consumption. • When EGR valve (7) opens, a part of the exhaust gas (EGR gas) flows from exhaust manifold (12) through EGR piping to EGR cooler (6).

114E-5 SERIES

10-19

10 Structure and function EGR system circuit diagram

• The exhaust gas cooled by EGR cooler (6) flows through EGR valve (7) and mixes with the intake air in the air intake connector, and then flows in the air intake manifold (14).

10-20

114E-5 SERIES

10 Structure and function EGR valve

EGR valve

(ENG107-A9K1-041-K-00-A)

a The shape is subject to machine models.

1. Valve 2. Spring 3. Power piston 4. Spool 5. Spring 6. EGR valve lift sensor 7. EPC valve (for EGR valve) 8. EPC valve (for KVGT) A: EGR gas inlet (from EGR cooler) B: EGR gas outlet (to intake manifold) C: Servo drive oil inlet D: Servo drive oil outlet E: KVGT control oil pressure outlet F: KVGT drive oil pressure outlet Structure • The EGR valve consists of the EGR gas flow control mechanism and the EPC valves • There are two EPC valves, one for the EGR valves control and one for the KVGTcontrol.

114E-5 SERIES

10-21

10 Structure and function EGR valve

Operation

(ENG107-A9K1-044-K-00-A)

• Oil from the boost oil pump flows into the EGR valve from port (C). Control pressure from the EPC valve flows into port (E).

• Spool (4) is pressed to the right by the reaction force of spring (5), and EGR valve (1) is closed by the reaction force of spring (2) Therefore, exhaust gas from the EGR cooler does not flow to the intake side.

• To open EGR valve (1), first the control pressure from the EPC valve enters port (E). Spool (4) moves to a position whereat this control pressure and the force of spring (5) are balanced.

• The hydraulic circuit in power piston (3) opens, and then the oil from the boost oil pump entering from port (C) pushes power piston (3) to the left.

• Oil from the boost oil pump acts on power piston (3) and generates force (Fp).

• When force (Fp) becomes larger than reaction force (Fs) of spring (2), EGR valve (1) opens and then exhaust gas will flow to the intake side.

• Since the hydraulic circuit to spool (4) is closed by movement of power piston (3), power piston (3) stops at a position determined by spool (4).

• The valve position is controlled by the engine controller by controlling the spool position with the control pressure of the EPC valve.

• A servo mechanism prevents external force applied to valve (1) from acting on spool (4), which is in contact with power piston (3).

• Position of spool (4) is sensed by the EGR valve lift sensor.

10-22

114E-5 SERIES

10 Structure and function EGR cooler

EGR cooler

(ENG107-A9L0-041-K-00-A)

a The shape is subject to machine models.

1. Tube A: EGR gas inlet B: Air vent C: Coolant outlet D: EGR gas outlet (to EGR valve) E: Coolant inlet

1. Flat tube 2. Inner fin

114E-5 SERIES

10-23

10 Structure and function EGR cooler

Operation

(ENG107-A9L0-044-K-00-A)

• The EGR gas enters from (A) and flows through 11 flat tubes (1).

• Coolant enters from (E) and flows around flat tube (1) in shell and then goes out from (C).

• The EGR gas is effectively cooled by flat tubes (1) with inner fins (2) and flows out from EGR gas outlet (D).

10-24

114E-5 SERIES

10 Structure and function KCCV layout drawing

KCCV layout drawing

(ENG114-A180-04D-K-01-A)

KCCV: Abbreviation for KOMATSU Closed Crankcase Ventilation a D65EX-17 is shown as an example. The shape is subject to machine models.

1. KCCV ventilator 114E-5 SERIES

10-25

10 Structure and function KCCV layout drawing

2. KVGT 3. Breather 4. Flywheel housing 5. Check valve 6. CDR valve 7. Crankcase pressure sensor A: Blowby gas (from flywheel housing) B: Blowby gas from which engine oil was removed (to KVGT) C: Engine oil (to oil pan) • Blowby gas has been emitted to the atmosphere so far. Since the emission regulation has become strict and blowby gas must be controlled now, the blowby gas intake recirculation system is employed.

• Blowby gas (A) contains ingredients of the engine oil. If it is recirculated to KVGT (2) as it is, it causes the following problems. To prevent this, a filter is installed to KCCV ventilator (1) to remove the engine oil.

1. Lowering of performance of turbocharger and aftercooler caused by sticking engine oil 2. Abnormal combustion in engine 3. Malfunction of each sensor caused by sticking engine oil • This system is not adopted to HB335-1, HB335LC-1, HB365-1, and HB365LC-1.

Blowby gas is released to atmosphere similarly to SAA6D114E-3 for Tier3 regulation.

Operation

(ENG107-A180-044-K-00-A)

a The figure on the left shows the flow of blowby gas released to the atmosphere from conventional engines.

The figure on the right shows the flow of blowby gas recirculated to the intake system by the KCCV ventilator.

1. Air cleaner 2. KVGT 3. Aftercooler 4. Cylinder block (crankcase) 5. Breather

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114E-5 SERIES

10 Structure and function KCCV layout drawing

6. KCCV ventilator 7. Oil pan • Engine oil mist is removed from blowby gas (A) in cylinder block (4) by the filter in KCCV ventilator (6), and then the cleaned gas (B) is recirculated to the intake side of the KVGT. • Removed engine oil (C) flows through a check valve and falls to the oil pan.

114E-5 SERIES

10-27

10 Structure and function KCCV ventilator

KCCV ventilator

(ENG114-A18H-041-K-01-A)

a The shape is subject to machine models. a KCCV is not mounted to HB335-1, HB335LC-1, HB365-1, and HB365LC-1.

1. Case 2. CDR valve 3. Crankcase pressure sensor 4. Relief valve 5. Impactor 6. Filter A: Blowby gas inlet (from breather) B: Blowby gas outlet (to KVGT intake side) C: Oil drain port (to oil pan)

Function

(ENG107-A18H-042-K-00-A)

• When blowby gas is recirculated to the intake side of the KVGT, the pressure inside the crankcase becomes negative, and dust may be sucked in through the crankshaft seals. Therefore, CDR valve (regulator valve) controls the pressure inside the crankcase.

• If the filter in the KCCV ventilator clogs, pressure inside the crankcase increases and oil may leak, so clog of filter is detected by crankcase pressure sensor.

• There are two types of filters that differ by the filter replacement method; the top load type (removed upward) and the bottom load type (removed downward).

Operation

(ENG107-A18H-044-K-00-A)

• Blowby gas enters (A) and large oil particles in the engine oil mist are separated when it flows through the hole of impactor (5) in filter (6).

• Small oil particles are separated by filter (6).

• The separated oil flows along the case wall to oil drain port (C), and then flows into the oil pan.

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114E-5 SERIES

10 Structure and function KCCV ventilator

• When the crankcase pressure becomes negative, CDR valve (2) operates to prevent the crankcase pressure from becoming excessively negative.

• The crankcase pressure sensor (3) senses the blowby gas pressure (crankcase pressure).

• If the engine controller judges from the value sensed by the crankcase pressure sensor (3) that the filter is clogged, it displays failure code CA555 and then displays CA556 if the pressure increases further.

• Relief valve (4) is installed inside case (1) and operates to protect the KCCV ventilator and engine when filter (6) is blocked.

CDR valve

(ENG107-A18A-041-K-00-A)

CDR: Abbreviation for Crankcase Depression Regulator

1. Diaphragm 2. Spring A: Crankcase side B: KVGT side (intake side) • The CDR valve is a regulator valve which prevents excessive negative crankcase pressure (P1).

• Normally, diaphragm (1) is pushed up by spring (2) and blowby gas flows from crankcase side (A) to KVGT side (intake side) (B).

• When intake air flow at KVGT side (intake side) (B) increases and crankcase pressure (P1) decreases, the reaction force of spring (2) yields to ambient pressure (P2). The diaphragm shuts the passage and temporarily blocks the flow.

• Then, when blowby gas accumulates in the crankcase and pressure (P1) recovers, the diaphragm is pushed up again and blowby gas starts to flow again.

114E-5 SERIES

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10 Structure and function KCCV ventilator

Forming of condensed water and emulsion

(ENG107-A18H-14H-K-00-A)

1. Air cleaner 2. KVGT 3. Aftercooler 4. Engine 5. Breather 6. KCCV ventilator 7. Oil pan Outline • If the machine is continuously operated in a low load condition at low ambient temperatures, the moisture in the blowby gas may condense instead of evaporating away. The water will flow through KCCV ventilator (6) to oil pan (7). The following occurs: 1.

2.

3.

4.

Moisture in the blowby gas condenses inside KCCV piping (A).

The condensed water flows through the drain circuit to the oil pan.

The water in the oil pan evaporates.

When the vapor condenses again at a relatively cool place inside the engine, it mixes with oil and forms a milky mixture. This mixture is so-called "mayonnaise sludge" (*). *: A mixture of oil and water, emulsified like mayonnaise (emulsion) 5. Mayonnaise sludge will deposit during low load operation when various parts in the engine are not warmed up enough. • Mayonnaise sludge is formed at low temperature areas that cause condensation, such as inside of breather (B), back side of head cover (C), and dipstick (D).

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114E-5 SERIES

10 Structure and function KCCV ventilator

• Mayonnaise sludge will evaporate away as the engine is operated under load and the engine oil temperature increases. • Mayonnaise sludge found in oil is harmless, however, when the engine coolant is found in oil, the engine must be checked for coolant leaks.

114E-5 SERIES

10-31

10 Structure and function KDPF

KDPF

(ENG114-A9H0-041-K-01-A)

KDPF: Abbreviation for Komatsu Diesel Particulate Filter a The shape is subject to machine models. a KDPF is not mounted to HB335-1, HB335LC-1, HB365-1, and HB365LC-1.

1. Inlet unit 2. KDOC inlet temperature sensor 3. KDOC outlet temperature sensor 4. KCSF unit 5. Centralized connector box 6. KDPF outlet temperature sensor 7. Outlet unit 8. KDPF differential pressure sensor port 9. KDPF differential pressure sensor 10. KDPF differential pressure sensor port 11. KDOC unit 12. Hanger bracket 13. Sensor bracket 14. Sensor bracket band 15. Water drain port A: From KVGT B: Exhaust C: Water drain • KDPF consists of inlet unit (1) which receives the exhaust gas, KDOC unit (11) which houses the oxidation catalyzer, KCSF unit (4) which houses the soot-capturing filter with catalyzer, and outlet unit (7) which

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114E-5 SERIES

10 Structure and function KDPF

• •

• • • • • • •

contains the "weir" to discharge the exhaust gas and prevent rainwater from entering KCSF unit (4) through the outlet.

KDOC unit (11) consists of ceramic honeycomb with oxidation catalyzer.

The ceramic honeycomb works to properly oxidize NO (nitrogen monoxide) contained in the exhaust gas into NO2 (nitrogen dioxide) and burn the fuel injected during automatic regeneration (*1) and manual stationary regeneration.

The ceramic honeycomb is protected with a mat made of special fibers to prevent breakage of the ceramic under the vibrations from the engine and chassis.

This mat also protects the outside of KDPF from being heated by the ceramic which becomes hot during operation.

KCSF unit (4) also consists of ceramic honeycomb with oxidation catalyzer, similarly to KDOC unit (11).

This ceramic honeycomb captures soot.

Inside KCSF, there are many cells partitioned by ceramic walls. Cells plugged at the inlet side and cells plugged at the outlet side are alternately arranged.

KDPF has 3 temperature sensors and one differential pressure sensor (integrated sensor of KDPF differential pressure sensor and KDPF outlet pressure sensor).

These 3 temperature sensors are used to monitor the functions of KDOC and KCSF and troubleshoot various items by combining the sensed temperatures.

The differential pressure sensor detects the soot level accumulated in KCSF by detecting the pressure difference over KCSF. It is also used to troubleshoot many items, similarly to the temperature sensors.

*1: Soot purification (oxidation) treatment k The

surface and nearby piping of KDPF are very hot while the engine is running and for a time after the engine is stopped. When you are required to work near KDPF, take extreme care not to get burnt.

Function

(ENG107-A9H0-042-K-00-A)

A: Flow of exhaust gas 1 KDOC (oxidation catalyzer) 2 KCSF 3 Sealing (ceramic) 114E-5 SERIES

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10 Structure and function KDPF

4 Cell 5 Ceramic honeycomb • KDPF is installed to meet the latest very severe emission regulations. It captures almost all PM (Particulate Matter) contained in the engine exhaust gas to clean the exhaust gas.

• KCSF (2) is made of ceramic. Inside KCSF, there are many cells partitioned by ceramic walls. Cells plugged at the inlet side and cells plugged at the outlet side are alternately arranged.

• The soot deposited in KCSF (2) are naturally oxidized and burned away by the effect of KDOC (1), in operating conditions with relatively high exhaust gas temperatures. (This is referred to as "passive regeneration".)

• On the other hand, when the exhaust temperature is relatively low, in conditions such as continued low load operations, the deposit of soot in KCSF (2) increases.

• The engine controller continuously monitors the amount of deposited soot by estimating from the operating conditions and calculating from the signals of the differential pressure sensor installed to KCSF (2).

• When the soot deposit exceeds a certain level, and the engine is operated with the exhaust gas temperature exceeding a certain level, the engine controller executes "automatic regeneration" to burn (oxidize) the soot.

• During automatic regeneration, the engine controller automatically controls the fuel injection timing and the KVGT to raise the exhaust temperature. This operation is called "exhaust temperature-raising control".

• As the exhaust temperature increases, the engine controller automatically performs calculations based on the exhaust temperature at KDOC (1) inlet and flow of the exhaust gas, so that KCSF (2) can efficiently burn (oxidize) the soot.

• KDOC (1) burns (oxidizes) the soot by utilizing the function of the catalyzer.

• Automatic regeneration is not performed when regeneration is executed from the machine monitor, or when the outside air temperature is extremely low, and when the exhaust gas temperature is not high enough to burn soot because the engine has been operated at low loads for a while. Thus, soot deposit in the KCSF (2) will increase.

• If the soot deposit in the KCSF (2) exceeds a certain level, it will be necessary to perform "manual stationary regeneration" to burn away (oxidize) the soot in the KCSF (2).

• If the soot deposit exceeds the acceptable level, the exhaust gas flow will be restricted. This can increase fuel consumption, degrade engine combustion, or cause other problems.

• If the soot deposit exceeds the limit to safely perform "manual stationary regeneration", the KDPF fails and replacement becomes unavoidable. Make sure to follow the procedures in the Operation and Maintenance Manual when performing "manual stationary regeneration"

Types of regeneration

(ENG107-A9H0-042-K-01-A)

a Regeneration refers to a process of purifying (oxidizing) the soot deposited in the soot collecting filter (KCSF) inside the KDPF. 1. Passive regeneration When the exhaust temperature is relatively high, the catalyst effect of the KDOC to oxidize soot will be stronger and the soot deposit in the KCSF will be naturally burned away.

2. Active regeneration 1) Automatic regeneration If the soot deposit exceeds a certain level, the engine controller switches to exhaust temperatureraising control (*1), performs fuel dosing (*2), and automatically starts the regeneration process.

Another type of automatic regeneration is performed by the engine controller at certain intervals, regardless of the amount of soot deposited in the KCSF. *1: The fuel injection timing and the KVGT are controlled to raise the exhaust temperature. *2: Fuel is injected to increase the exhaust temperature and accelerate the regeneration process. No. 1, 2, and 3 injectors are used for fuel dosing.

2) Manual stationary regeneration (*3) When the exhaust temperature does not reach a certain level due to the machine operating condition, or when regeneration is disabled by the operator, automatic regeneration will not be performed and the soot deposit in the KCSF may increase. In such conditions, the machine monitor displays a manual stationary regeneration request on the screen. The operator must perform regeneration by operating the machine monitor on its screen. A regeneration feature is also provided for the technician who should use this feature from the machine monitor menu after engine controller replacement, KDPF replacement, and KCSF ash cleaning. (= Regeneration for service (*3))

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10 Structure and function KDPF

*3:For details, see the Shop Manual for the applicable machine.

• A KDPF drying feature is provided to prevent excessive accumulation of unburned fuel in the KDPF when the machine is operated for a long time with low exhaust temperature.

• When certain conditions are met, the engine controller automatically switches control to increase the exhaust temperature to dry the KCSF. If some of the conditions for automatic drying are not met, manual stationary regeneration may be requested. a Follow the procedures in the Operation and Maintenance Manual when starting and stopping KDPF regeneration. a Be sure to use ultra-low-sulfur diesel fuel. Non-specified fuels may cause KDPF failure. a Be sure to use the specified Komatsu genuine oil for the KDPF. Non-specified oils may cause KDPF clogging in a short time, resulting in increased fuel consumption or KDPF failure. a Do not modify the KDPF itself or exhaust pipes. Modifications disturb normal operation of the KDPF, leading to a failure. a Do not apply impacts to the KDPF by stepping on, dropping, or striking it. The KDPF contains a ceramic honeycomb, which can be damaged by strong impacts. a The engine controller performs automatic regeneration even when the amount of soot deposit is low. Since this is programmed to maintain the KDPF performance, this is normal. a During automatic regeneration and manual stationary regeneration, the KVGT automatically operates and the engine sound changes. The flow of exhaust gas through the KDPF changes and the exhaust sound changes, but this is normal. a During automatic regeneration and manual stationary regeneration, especially at low temperatures, white smoke may come out from the exhaust pipe for a short time, but this is normal. Be sure to perform regeneration at a well ventilated place since carbon monoxide can be produced. a During automatic regeneration and manual stationary regeneration, a strange odor may be smelled from the exhaust pipe, but this is normal. a During automatic regeneration and manual stationary regeneration, the exhaust temperature at the exhaust pipe can exceed 650 °C. Make sure that there is no flammable material near the exhaust system to prevent fire. Make sure that nobody is standing in front of the exhaust pipe, and pay sufficient attention to safety of the environment. a KDPF temperature values are shown below for reference.

Not regenerating (idling) Regenerating (under exhaust temperature-raising control: 1,000 rpm)

114E-5 SERIES

DOC_In (KDOC inlet temperature sensor)

DOC_Out (KDOC outlet KDPF_Out (KDPF outlet temperature sensor) temperature sensor) 100 to 250 °C

100 to 250 °C

400 to 550 °C

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10 Structure and function Cylinder head

Engine main body parts Cylinder head

(ENG107-R402-001-K-00-A)

(ENG114-A100-041-K-00-A)

a The shape is subject to machine models.

1. Cylinder head 2. Cylinder head cover 3. Head bolt 4. Injector assembly

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10 Structure and function Cylinder head

Specifications

(ENG107-A100-030-K-00-A)

Cylinder head • Direct fuel injection type • Integral type • 4-valve Valve seat • Intake side: Valve seat inserts are press fitted • Exhaust side: Valve seat inserts are press fitted Injector assembly • Installation: Dry type (without sleeve)

114E-5 SERIES

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10 Structure and function Cylinder block

Cylinder block

(ENG114-A300-041-K-00-A)

a The shape is subject to machine models.

1. Main bearing cap 2. Main bearing cap bolt 3. Cylinder block 4. Camshaft bushing a: Center of crankshaft b: Cylinder block back side

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10 Structure and function Cylinder block

Specifications

(ENG114-A300-030-K-00-A)

Cylinder block • Crankshaft: 7 bearings • Camshaft section: 7 bearings Cylinder liner • Wet type • Finish of inside wall: plateau honing

114E-5 SERIES

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10 Structure and function Main moving parts

Main moving parts

(ENG114-R403-001-K-00-A)

a The shape is subject to machine models.

1. Crankshaft 2. Front crankshaft gear (42 teeth) 3. Main bearing 4. Connecting rod bearing 5. Connecting rod 6. Cylinder block 7. Cylinder liner 8. Piston 9. Connecting rod bushing 10. Piston pin 11. Top ring 12. Second ring

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10 Structure and function Main moving parts

13. Oil ring 14. Connecting rod cap 15. Connecting rod cap bolt 16. Main cap bolt 17. Main cap

Specifications

(ENG114-R403-030-K-01-A)

Crankshaft • Closed die forging • Journal induction hardening Piston • Toroidal combustion chamber for direct fuel injection • Aluminum piston (shaker) Piston ring

• Top ring (1): Barrel face, keystone, inner cut, and hard chrome plating • Second ring (2): Taper, and hard chrome plating • Oil ring (3): With coil expander, M-shape steal ring, and hard chrome plating Connecting rod D65EX-17、 D65PX-17、D65WX-17、PC360LC–10

114E-5 SERIES

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10 Structure and function Main moving parts

HB335–1, HB335LC–1, HB365–1, HB365LC–1

Specification • Closed die forging • The cap bolt is screwed-in type, torque plus angle method, and with lubrication hole.

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10 Structure and function Vibration damper

Vibration damper

(ENG114-A5E0-041-K-00-A)

a The shape is subject to machine models.

1. Vibration damper 2. Crankshaft pulley 3. Mounting bolt

Function

(ENG107-A5E0-042-K-00-A)

• The vibration damper absorbs the torsional vibration that acts on the crankshaft and prevents damage and abnormal wear of the crankshaft and gears.

114E-5 SERIES

10-43

10 Structure and function Timing gear

Timing gear

(ENG114-A5A0-041-K-00-A)

a The shape is subject to machine models.

1. Boost oil pump gear (24 teeth) 2. Idler gear (23 teeth) 3. Crankshaft gear (42 teeth) 4. Camshaft gear (84 teeth) 5. Supply pump gear (84 teeth)

Function

(ENG114-A5A0-042-K-00-A)

• Timing (crankshaft) gear (3) and camshaft gear (4) are in mesh to to time the opening-closing of the intake and exhaust valves to the up-down of the pistons.

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10 Structure and function Front cover

Front cover

(ENG114-A5B2-041-K-00-A)

a The shape is subject to machine models.

1. Front gear cover 2. Front gear housing 3. Gasket 4. Front seal cover 5. Front seal

114E-5 SERIES

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10 Structure and function Valve system

Valve system

(ENG114-A700-041-K-00-A)

• The shape is subject to machine models.

1. Camshaft gear (84 teeth) 2. Thrust plate 3. Camshaft 4. Intake valve 5. Exhaust valve 6. Valve spring 7. Valve seal 8. Valve cotter 9. Adjustment screw 10. Locknut 11. Rocker arm 12. Push rod 13. Tappet

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114E-5 SERIES

10 Structure and function Flywheel

Flywheel

(ENG114-A560-041-K-00-A)

a The shape is subject to machine models.

1. Flywheel housing 2. Starting motor 3. Ring gear (148 teeth) 4. Flywheel 5. Rear seal

Specifications

(ENG114-A560-030-K-00-A)

Rear seal • For wet type: Double lip

114E-5 SERIES

10-47

10 Structure and function Lubrication system parts layout drawing

Lubrication system

(ENG107-AB00-001-K-00-A)

Lubrication system parts layout drawing

(ENG114-AB00-04D-K-00-A)

a The D65EX-17 is shown as an example. The shape is subject to machine models.

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114E-5 SERIES

10 Structure and function Lubrication system parts layout drawing

1. EGR valve 2. Boost oil pump 3. KVGT 4. Engine oil filter

114E-5 SERIES

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10 Structure and function Lubrication system circuit diagram

Lubrication system circuit diagram

(ENG114-AB00-052-K-00-A)

1. Strainer 2. Oil pump 3. Regulator valve 4. Bypass valve 5. Oil cooler 6. Oil filter 7. Safety valve 8. KVGT lubyication 9. Main gallery lubrication 10. Lubyication of bearings 11. Boost oil pump 12. Regulator valve 13. EPC valve (for KVGT) 14. KVGT 15. EPC valve (for EGR valve) 16. EGR valve 17. Piston cooling gallery 18. Piston cooling 19. Oil pan

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10 Structure and function Oil pump

Oil pump

(ENG114-AB50-041-K-00-A)

a The shape is subject to machine models.

1. Drive gear (24 teeth) 2. Bushing 3. Drive shaft 4. Housing 5. Idler shaft 6. Idler gear (23 teeth) 7. Back plate 8. Inner rotor (drive rotor) 9. Outer rotor (planetary rotor)

Specifications

(ENG114-AB50-030-K-00-A)

• Type: Trochoid pump • Speed: Engine speed x 1.75

Function

(ENG107-AB50-042-K-00-A)

• The oil pump feeds engine oil which lubricates the inside of the engine.

• The pump is installed between the oil pan and regulator valve circuit, and is driven by the camshaft.

114E-5 SERIES

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10 Structure and function Boost oil pump

Boost oil pump

(ENG114-A9N0-041-K-00-A)

a The shape is subject to machine models.

1. Regulator valve A: Discharge port B: Suction port

Specifications

(ENG114-A9N0-030-K-00-A)

Oil pump • Type: Gear pump • Speed: Engine speed x 1.0 Regulator valve • Cracking pressure: 1.43 ± 0.1 MPa {14.6 ± 1 kg/cm2}

Function

(ENG107-A9N0-042-K-00-A)

• The boost oil pump feeds engine oil which drives the EGR valve and the KVGT. • The pump is installed between the main gallery and EGR valve and KVGT circuit, and is driven by the camshaft.

• The pump feeds oil pressure to the EGR valve drive, EGR valve control, KVGT drive, and KVGT control circuits.

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114E-5 SERIES

10 Structure and function Oil filter

Oil filter

(ENG114-ABC0-041-K-00-A)

a The shape is subject to machine models.

1. Filter cartridge 2. Safety valve 3. Plug 4. Filter head

Function

(ENG107-ABC0-042-K-00-A)

• During the engine lubrication process, impurities such as carbon, sludge, and wear particles will mix in the engine oil. The filter removes these impurities.

• A safety valve is provided to bypass the engine oil when the filter gets clogged.

• To make filter cartridge replacement easier, this is remotely mounted on some machines.

114E-5 SERIES

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10 Structure and function Oil cooler

Oil cooler

(ENG114-B810-041-K-00-A)

a The shape is subject to machine models.

1. Oil cooler core assembly 2. Oil pump 3. Regulator valve 4. Safety valve a: Oil pump gear b: Crankshaft gear

Specifications

(ENG114-B810-030-K-00-A)

Oil cooler • Number of element steps: 15

Function

(ENG107-B810-042-K-00-A)

• This is installed in the circuit between the regulator valve and oil filter to cool the engine oil.

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10 Structure and function Regulator valve

Regulator valve

(ENG114-ABD4-041-K-00-A)

a The oil filters layout, shape of oil pan and piping are subject to machine models.

1. Plug 2. Spring 3. Plunger valve 4. Oil filter 5. Safety valve 6. Oil cooler A: To oil cooler B: From lubricating oil pump C: To oil pan D: From lubricating oil filter E: From lubricating oil filter F: To main gallery

Specification

(ENG114-ABD4-030-K-00-A)

Cracking pressure: 517 kPa {5.3 kg/cm2}

114E-5 SERIES

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10 Structure and function Safety valve

Safety valve

(ENG114-ABD0-041-K-00-A)

a The shape is subject to machine models.

1. Plug 2. Spring 3. Plunger valve 4. Oil filter 5. Safety valve 6. Oil cooler A: To oil cooler B: From lubricating oil pump C: To oil pan D: From lubricating oil filter E: From lubricating oil filter F: To main gallery

Specifications

(ENG114-ABD0-030-K-00-A)

Cracking pressure: 345 kPa {3.5 kg/cm2}

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114E-5 SERIES

10 Structure and function Oil pan

Oil pan

(ENG114-AB20-041-K-00-A)

a The shape is subject to machine models.

1. Oil level gauge 2. Oil suction pipe 3. Oil pan 4. Oil level sensor 5. Drain valve

114E-5 SERIES

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10 Structure and function Fuel system parts layout drawing

Fuel system

(ENG107-AD00-001-K-00-A)

Fuel system parts layout drawing

(ENG114-AD00-04D-K-00-A)

a The shape is subject to machine models.

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114E-5 SERIES

10 Structure and function Fuel system parts layout drawing

1. Main filter 2. Injector 3. Inlet connector 4. Check valve 5. Supply pump 6. Common rail 7. High-pressure pipe 8. Pressure limiter valve 9. Feed pump A: From pre-filter B: To main filter

114E-5 SERIES

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10 Structure and function Fuel system circuit diagram

Fuel system circuit diagram

(ENG114-AD00-052-K-00-A)

1. Main filter 2. Supply pump 3. Injector 4. Common rail 5. Check valve 6. Pressure limiter valve 7. Fuel tank 8. Water separator 9. Pre-filter 10. Priming pump 11. Lift pump 12. ECM cooling plate 13. Check valve 14. Feed pump

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114E-5 SERIES

10 Structure and function Fuel system circuit diagram

Operation

(ENG114-AD00-044-K-00-A)

• The fuel system is of an electronically controlled high-pressure common rail type. The high-pressure common rail system consists of four main components: • Feed pump (low pressure pump) (12), supply pump (high-pressure pump) (2), common rail (4), and injectors (3).

• The fuel system uses injectors (3) driven by solenoids.

• The engine controller (EC) controls the solenoid in each injector (3) to control the fuel supply and timing to the injector (3).

• By controlling the solenoids electronically, the flow and timing are precisely controlled.

2. Supply pump 3. Injector 4. Common rail EC: Engine controller PS: Common rail pressure sensor • Supply pump (2) sends high-pressure fuel to common rail (4). High-pressure fuel is held in common rail (4).

• The engine controller (EC) controls the solenoid in each injector (3) to control the fuel supply and timing to the injector (3).

• Fuel flows through the pre-filter (with a water separator) to feed pump (12).

• Fuel discharged from feed pump (12) is filtered at main filter (1) and then enters supply pump (2).

• Fuel in supply pump (2) is pressurized in the two plunger-pump.

• Common rail (4) holds fuel and acts as a fuel manifold to distribute fuel to the supply line of each injector (3).

• Engine controller (EC) monitors the pressure sent from supply pump (2) to common rail (4) by using common rail pressure sensor (PS) provided inside common rail (4).

• The pressure detected by common rail pressure sensor (PS) is used by engine controller (EC) to regulate the fuel output from supply pump (2).

• Pressure limiter valve (6) (common rail pressure relief valve) is also installed in common rail (4).

114E-5 SERIES

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10 Structure and function Fuel system circuit diagram

• Pressure limiter valve (6) is a safety valve to release pressure if the common rail pressure exceeds the threshold setting.

• Fuel released from pressure limiter valve (6) flows from common rail (4) through a fuel return line to the fuel tank.

• High-pressure fuel flows to the side of injector (3), and when the solenoid is energized, the needle inside is lifted and fuel is injected.

Injector and inlet connector • Since the clearance inside the injector nozzle is extremely small, dirt will cause sticking of the injector nozzle. Before servicing the fuel system, it is important to clean all fuel connections.

• Before starting the repair work of the fuel system, cap or cover all open fuel connections.

• High-pressure fuel is supplied from common rail (7) through high-pressure pipe (11) and inlet connector (1) to injector (17).

• By tightening retaining nut (18) of inlet connector (1), inlet connector (1) is pressed against the body of injector (17). High-pressure pipe (11) is connected to inlet connector (1) by tightening the sleeve nut.

• Connection between inlet connector (1) and high-pressure pipe (11) is extremely important. If the tightening of retaining nut (18) is insufficient, the connecting surfaces are not sealed, and high-pressure fuel will leak.

• If the tightening torque of retaining nut (18) is excessive, inlet connector (1) and injector (17) will be deformed, also leading to a leak of high-pressure fuel.

• Since these leaks occur inside the parts, they cannot be found visually. This can result in failure codes, low engine output, and engine starting problems.

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10 Structure and function Fuel system circuit diagram

• Inlet connector (1) contains an edge filter to break small foreign materials in the fuel. The edge filter uses high pulsation pressure to break particles into smaller pieces so that they can flow through the injector fuel passages.

• All injectors return fuel to a common return circuit in the cylinder head.

• Excessive fuel flows from the return circuit through the spill tube installed to the rear of the cylinder head to the fuel tank.

• A check valve is installed to the rear of the cylinder head, where the spill tube is installed.

• The cylinder head and spill tube are connected with a quick disconnect fitting or an eye joint.

114E-5 SERIES

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10 Structure and function Supply pump

Supply pump

(ENG114-AD70-041-K-00-A)

a The shape is subject to machine models.

1. Feed pump 2. Supply pump 3. IMV (*) solenoid connector * IMV: Abbreviation for Inlet Metering Valve A: Fuel inlet (from pre-filter) B: Fuel outlet (to main filter) C: Fuel inlet (from main filter) D: Fuel outlet (to common rail) E: Drain (to fuel tank)

Specifications

(ENG114-AD70-030-K-00-A)

• Type: Plunger pressure feed • Lubrication method: lubricated by fuel

Function

(ENG107-AD70-042-K-00-A)

• The supply pump consists of a feed pump (low-pressure pump) and a supply pump (high-pressure pump) is driven by the power from the camshaft.

• The feed pump (low-pressure pump) supplies fuel to the main filter.

• The supply pump (high-pressure pump) sends fuel to the common rail.

10-64

114E-5 SERIES

10 Structure and function Supply pump

Operation

(ENG114-AD70-044-K-00-A)

• A lift pump is used for priming the pump at start- up.

• The lift pump runs for approximately 60 seconds after key on. Once the engine is started, the feed pump is able to maintain prime without any assistance from the lift pump.

• The ECM and ECM cooling plate must be removed for access to the lift pump and lift pump fuel lines.

• This is accomplished by disconnecting the engine harnesses and the quick disconnect type fuel lines first.

Removal of the ECM cooling plate capscrews allows the ECM, cooling plate, lift pump and lift pump plumbing to be removed as one assembly.

• The feed pump output is routed to a 2- micron fuel main filter. The filtered fuel returns to the fuel pump actuator housing.

• The supply pump is driven by the engine camshaft. The feed pump is driven by the pump camshaft through an internal coupling.

114E-5 SERIES

10-65

10 Structure and function Supply pump

• Each of the two plunger-pump is driven by a three lobed camshaft. The pump camshaft is located in the cam housing module by tapered roller bearings.

• The bearings that support the pump camshaft, as well as the tappets, rollers and pump camshaft itself are lubricated with engine oil. These are the only components in the pump lubricated with engine oil.

• Engine oil to the supply pump is supplied through a drilling in the engine gear housing. The oil passes from the engine gear housing to the supply pump cam housing.

• A small O-ring in a recess on the back of the engine gear housing is used to seal this passage.

• Pressurized fuel from the feed pump is supplied to the supply pump actuator. The fuel pump actuator is opened or closed by the ECM to maintain the appropriate common rail pressure.

• An air-bleed orifice fitting in the supply pump actuator housing aids in purging air from the fuel supply.

• Because of the air-bleed orifice fitting, some fuel that is supplied by the gear pump will return to drain at all times.

10-66

114E-5 SERIES

10 Structure and function Supply pump

• Fuel that is metered past the supply pump actuator will enter inlet drilling in the supply pump inlet drilling and pass the inlet check valve and fill the pumping chamber by pressing the plunger-pump downward. • When the camshaft pushes the plunger-pump upward, fuel will reach common rail pressure and cause the outlet check valve to lift. Fuel will then enter the outlet drilling of the supply pump and exit the high pressure fuel line to the common rail.

114E-5 SERIES

10-67

10 Structure and function Pre-filter

Pre-filter

(ENG107-AEA0-041-K-00-A)

a The shape is subject to machine models.

1. Connector 2. Clear bowl 3. Filter cartridge 4. Water-in-fuel sensor 5. Hand primer (priming pump) 6. O-ring 7. Drain valve

Function

(ENG107-AEA0-042-K-00-A)

• Fuel from the fuel tank flows through the pre-filter to the supply pump.

• The pre-filter is a fuel filter with a water separator and collects the water removed from the fuel.

• A water-in-fuel sensor is provided to detect the amount of separated water.

10-68

114E-5 SERIES

10 Structure and function Main filter

Main filter

(ENG114-AED0-041-K-00-A)

a The shape is subject to machine models.

1. Pressure pickup plug 2. Filter head 3. Cartridge

Function

(ENG107-AED0-042-K-00-A)

• Fuel from the feed pump (low-pressure pump) flows through the main filter to the supply pump (highpressure pump).

• The main filter removes impurities from the fuel.

• To make cartridge replacement easier, this is remotely mounted on some machines.

114E-5 SERIES

10-69

10 Structure and function Cooling system parts layout drawing

Cooling system

(ENG107-B110-001-K-00-A)

Cooling system parts layout drawing

(ENG114-B110-04D-K-00-A)

a The D65EX-17 is shown as an example. The shape is subject to machine models.

1. EGR cooler 2. KVGT 3. Water pump 4. Oil cooler A: From radiator B: To radiator

10-70

114E-5 SERIES

10 Structure and function Cooling system circuit diagram

Cooling system circuit diagram

(ENG114-B110-052-K-00-A)

1. Radiator 2. Thermostat 3. Cylinder head 4. KVGT 5. EGR cooler 6. Cylinder block 7. Engine oil cooler 8. Water pump a: Flow when thermostat is open b: Flow when thermostat is closed

114E-5 SERIES

10-71

10 Structure and function Cooling system circuit diagram

1. Coolant inlet from radiator 2. Water pump suction 3. Coolant flow through lubricating oil cooler 4. Block lower water manifold (to cylinders) 5. Coolant supply to cylinder head 6. Coolant return from cylinder head 7. Block upper water manifold 8. Thermostat bypass 9. Coolant return to radiator

10-72

114E-5 SERIES

10 Structure and function Drive pulley

Drive pulley

(ENG114-B110-041-K-00-A)

Water pump drive

(ENG114-B400-041-K-00-A)

a The shape is subject to machine models.

1. V-belt 2. Crankshaft pulley 3. Tension pulley 4. Water pump 5. Alternator A: To radiator B: From radiator a, b, c, d, e: Outside diameter of pulley

114E-5 SERIES

10-73

10 Structure and function Drive pulley

Specification

(ENG114-B400-030-K-00-A)

Outside diameter of pulley Unit: mm Engine

Machine model

D65EX-17 SAA6D114ED65PX-17 5 D65WX-17

10-74

a (Water pump)

b (Alternator)

c (Tension)

d (Idler)

e (Crank)

102

80

73

—

219

114E-5 SERIES

10 Structure and function Drive pulley

Fan drive

(ENG114-B400-041-K-01-A)

a The shape is subject to machine models.

1. V-belt 2. Tension pulley 3. Water pump 4. Auto-tensioner 5. Alternator 6. Fan pulley 7. Fan 8. Crankshaft pulley 9. Idler pulley A: To radiator (Coolant) B: From radiator (coolant) a, b, c, d, e, f : Outside diameter of pulley • Since auto-tensioner (4) is installed, tension pulley (2) automatically adjusts tension of V-belt (1) to keep same level.

114E-5 SERIES

10-75

10 Structure and function Drive pulley

Specifications

(ENG114-B400-030-K-04-A)

Outside diameter of pulley Unit: mm Engine

Machine model

PC360LC–10 HB335–1 SAA6D114HB335LC–1 E-5 HB365–1 HB365LC–1

10-76

a (Water pump) 102 102

b (Alternator) c (Tension) d (Idler)

e (Idler)

f (Crank)

80

73

73

74

219

80

73

73

–

219

114E-5 SERIES

10 Structure and function Water pump

Water pump

(ENG107-BA10-041-K-00-A)

a The shape is subject to machine models.

1. Impeller 2. Water seal 3. Pump body 4. Pulley 5. Drive shaft A: Coolant inlet B: Coolant outlet (to engine)

Specifications

(ENG107-BA10-030-K-00-A)

• Type: Centrifugal type, poly V-belt drive

Function

(ENG114-BA10-042-K-00-A)

• The water pump circulates coolant through the entire engine to prevent engine from overheating.

• Engine power is transmitted to the pulley via a V-belt to drive the impeller.

114E-5 SERIES

10-77

10 Structure and function Thermostat

Thermostat

(ENG114-BA30-041-K-00-A)

a The shape is subject to machine models.

1. Piston 2. Spring 3. Case 4. Bypass spring 5. Bypass valve

10-78

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10 Structure and function Thermostat

Specifications Engine

SAA6D114E-5

114E-5 SERIES

(ENG114-BA30-030-K-00-A)

Machine model D65EX-17 D65PX-17 D65WX-17 PC360LC–10 HB335–1 HB335LC–1 HB365–1 HB365LC–1

Cracking temperature (°C)

Full open temperature (°C)

Valve Lift (mm)

70 ± 2

83

Min. 10

81 ± 2

94

Min. 10

10-79

10 Structure and function Alternator

Electrical equipment Alternator

(ENG107-AK50-001-K-00-A)

(ENG-AKK0-001-K-00-A)

Alternator with built-in regulator (Open type, 60A)

(ENG114-AKK0-041-K-00-A)

a The shape is subject to machine models.

1. Alternator 2. Alternator pulley 3. Terminal E 4. Terminal B 5. Terminal R 6. Internal electric circuit diagram 6A. Field coil 6B. Initial energizing resistance 6C. Regulator

10-80

114E-5 SERIES

10 Structure and function Alternator

Specifications Engine

(ENG114-AKK0-030-K-00-A)

Machine model

D65EX-17 D65PX-17 D65WX-17 SAA6D114E- PC360LC–10 5 HB335–1 HB335LC–1 HB365–1 HB365LC–1

114E-5 SERIES

Type

Open type, manufactured by Nikko Electric Industry

Pulley SpecificaOutside Number of tion diameter stage (mm)

Weight (kg)

Poly Vribbed with 8 ribs

11.0

24 V, 60 A

80

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10 Structure and function Alternator

Alternator with built-in regulator (Open type, 90A)

(ENG114-AKK0-041-K-01-A)

a The shape is subject to machine models.

1. Alternator 2. Alternator pulley 3. Terminal B 4. Terminal E 5. Terminal R 6. Internal electric circuit diagram 6A. Field coil 6B. Initial energizing resistance 6C. Regulator

10-82

114E-5 SERIES

10 Structure and function Alternator

Specifications Engine

(ENG114-AKK0-030-K-01-A)

Machine model

D65EX-17 (available as an option) D65PX-17 SAA6D114E-5 (available as an option) D65WX-17 (available as an option)

114E-5 SERIES

Type

Specifications

Outside diameter (mm)

Weight (kg)

Open type, manufactured by Nikko Electric Industry Co.

24 V, 90 A

80

19

10-83

10 Structure and function Starting motor

Starting motor For 7.5kW

(ENG-AK70-001-K-00-A)

(ENG114-AK70-041-K-00-A)

a The shape is subject to machine models.

1. Pinion gear 2. Magnetic switch 3. Starting motor (body) 4. Terminal B 5. Terminal C 6. Air hole for waterproof test 7. External electrical circuit diagram 7A. Safety relay 7B. Starting motor S: To terminal C of starting motor R: To terminal R of alternator E: To ground 8. Connector specification A Type: 2P connector (male) B Type: 2P drip proof connector (male)

10-84

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10 Structure and function Starting motor

Specifications Engine

(ENG114-AK70-030-K-04-A)

Machine model

D65EX-17 D65PX-17 D65WX-17 SAA6D114HB335–1 E-5 HB335LC–1 HB365–1 HB365LC–1

114E-5 SERIES

Type

Specification

Water-proof, oil-proof type, manufactured by Nikko Electric Industry

24 V, 7.5 kW

Number of Weight Connector specifica(kg) pinion teeth tions

12

15.5

B

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10 Structure and function Starting motor

For 11kW

(ENG114-AK70-041-K-01-A)

a The shape is subject to machine models.

1. Pinion gear 2. Starting motor assembly 3. Magnetic switch 4. Terminal B 5. Terminal C 6. Safety relay 7. External connection diagram (2–pole connector type) 7A. Safety relay section 7B. Starting motor section E: To chassis ground R: To alternator terminal R S: To terminal C of starting motor A Type : 2P connector (male) B Type : 2P drip proof connector (male)

10-86

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10 Structure and function Starting motor

Specifications Engine

(ENG114-AK70-030-K-05-A)

Machine model

D65EX-17(available as an option) D65PX-17(available as an option) D65WX-17(available as an option) PC360LC–10 SAA6D114- HB335–1(available as an option) E-5 HB335LC–1 (available as an option) HB365–1(available as an option) HB365LC–1 (available as an option)

114E-5 SERIES

Type

Specification

Water-proof, oilproof type, manufactured by Nikko Electric Industry

24 V, 11 kW

Number of Weight Connector pinion teeth (kg) specifications

11

18

B

10-87

10 Structure and function Intake air heater

Intake air heater

(ENG114-AM51-041-K-00-A)

1. Heater coil 2. Housing 3. Internal electrical circuit diagram

Specifications

(ENG107-AM51-030-K-00-A)

• Type of heater: Electrical intake air heater (ribbon heater) • Rated voltage: 22 V (DC) • Load current: 100 A

10-88

114E-5 SERIES

10 Structure and function Engine wiring harness

Engine wiring harness

(ENG114-AK51-041-K-00-A)

a The D65EX-17 is shown as an example. The shape is subject to machine models.

1. To KVGT speed sensor 2. To KVGT position sensor 114E-5 SERIES

10-89

10 Structure and function Engine wiring harness

3. To charge (boost) pressure & temperature sensor 4. To injector wiring harnesses 5. To connector box 6. To EGR valve lift sensor 7. To common rail pressure sensor 8. To EGR orifice temperature sensor 9. To ambient pressure sensor 10. To engine controller 11. To Bkup (camshaft) speed sensor 12. To supply pump 13. To machine wiring harness 14. To coolant temperature sensor 15. To CAN terminating resistor 16. To oil pressure switch 17. To exhaust manifold pressure sensor 18. To Ne (crankshaft) speed sensor

10-90

114E-5 SERIES

10 Structure and function Engine controller

Engine controller

Function

(PC220-AP70-041-K-00-A)

(ENG107-AP70-042-K-00-A)

• The engine controller CM2250, co-developed by Komatsu and Cummins, is adopted.

• It performs calculations based on input signals from various sensors to output signals for optimized engine control.

• The engine controller shares information with other controllers on the machine through the network (CAN) and optimally controls the engine according to the machine conditions.

• By mounting the controller on the engine, serviceability in the field is improved.

• The controller is mounted with rubber vibration isolators to reduce the effect of vibration.

114E-5 SERIES

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10 Structure and function Engine controller

Engine controller system diagram

10-92

(ENG107-AP70-052-K-00-A)

114E-5 SERIES

10 Structure and function Engine controller

Input and output signals

(PC-AP70-03C-K-00-A)

• The following is the list of the symbols used for signal category in the input/output signal table.

A: Power supply B: Input C: Ground/Shield/Return D: Output E: Communication DRC26-60P(1)[ECM J1(CN-CE01)] Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 114E-5 SERIES

Signal name (*1) (*1) Crankcase pressure sensor (*1) Charge temperature sensor Intake air temperature (MAF) sensor CAN_C (+) CAN_B (+) (KOMNET/r) Bkup (camshaft) speed sensor (+) (*1) (*1) (*1) GND Coolant temperature sensor Charge pressure sensor Ambient pressure sensor CAN_C (-) CAN_B (-) (KOMNET/r) (*1) (*1) Sensor power supply (12 V) GND Mass air flow and temperature sensor Water-in-fuel sensor (*1) Ne (crankshaft) speed sensor (+) (*1) (*1) (*1) IMV(+) Engine oil pressure switch GND (*1) (*1) (*1) Sensor power supply (5 V) NE (crankshaft) speed sensor (-) (*1) (*1) IMV (-) (*1) (*1)

Signal category — — B — B B E E B — — — C B B B E E — — A C B B — B — — — D B C — — — A C — — C — —

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10 Structure and function Engine controller

Pin No. 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60

Signal name Injector #4 (+) Injector #5 (+) Injector #6 (+) Injector #3 (+) Injector #2 (+) Injector #1 (+) (*1) (*1) (*1) (*1) Injector #4 (-) Injector #5 (-) Injector #6 (-) Injector #3 (-) Injector #2 (-) Injector #1 (-) GND Sensor power supply (5 V)

Signal category D D D D D D — — — — C C C C C C C A

*1: Never connect these pins. Malfunctions or failures may occur.

DRC26-60P(2)[ECM J2(CN-CE02)] Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

10-94

Signal name (*1) (*1) (*1) (*1) (*1) EGR actuator (+) (*1) (*1) (*1) KVGT actuator (+) (*1) (*1) (*1) (*1) (*1) EGR actuator (-) (*1) GND (*1) KVGT actuator (-) GND (*1) (*1) CAN_B (+) CAN_B (-) (*1) (*1) (*1) (*1) Sensor power supply (5 V)

Signal category — — — — — D — — — D — — — — — C — C — C C — — E E — — — — A 114E-5 SERIES

10 Structure and function Engine controller

Pin No. 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60

Signal name Sensor power supply (5 V) KVGT speed sensor (+) KVGT speed sensor (-) Exhaust manifold pressure sensor (*1) (*1) (*1) KVGT position sensor (*1) (*1) (*1) (*1) (*1) Common rail pressure sensor (*1) GND GND EGR orifice temperature sensor (*1) (*1) (*1) (*1) (*1) (*1) (*1) (*1) (*1) (*1) EGR valve lift sensor (*1)

Signal category A B C B — — — B — — — — — B — C C B — — — — — — — — — — B —

*1: Never connect these pins. Malfunctions or failures may occur.

DRC26-60P(3)[CN-CE03] *1: Never connect these pins. Malfunctions or failures may occur.

Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 114E-5 SERIES

Signal name Continuous power supply (24 V) Continuous power supply (24 V) Starting switch ACC signal Intake air heater relay (+) (*1) (*1) (*1) (*1) System operating lamp (*1) Continuous power supply (24 V) Continuous power supply (24 V) GND (*1) (*1) (*1)

Signal category A A B D — — — — D — A A C — — —

10-95

10 Structure and function Engine controller

Pin No. 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60

10-96

Signal name CAN_A (+) (KOMNET/c) CAN_A (-) (KOMNET/c) GND (*1) GND GND (*1) (*1) (*1) (*1) (*1) (*1) (*1) (*1) GND GND (*1) (*1) (*1) (*1) (*1) (*1) (*1) (*1) GND Sensor power supply (5 V) GND (*1) KDOC inlet temperature sensor (*1) (*1) KDOC outlet temperature sensor Idle validation signal 1 Idle validation signal 2 Throttle signal Sensor power supply (5 V) (*1) KDPF outlet temperature sensor KDPF differential pressure sensor (*1) (*1) KDPF outlet pressure sensor (*1) (*1)

Signal category E E C — C C — — — — — — — — C C — — — — — — — — C A C — B — — B B B B A — B B — — B — —

114E-5 SERIES

10 Structure and function Sensor

Sensor

(ALL-E700-001-P-00-A)

Sensors layout drawing

114E-5 SERIES

(ENG114-AK50-04D-K-00-A)

10-97

10 Structure and function Sensor

List of sensor No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 –

(ENG114-AK50-056-K-00-A)

Sensor KVGT speed sensor KVGT position sensor KDOC inlet temperature sensor KDPF differential pressure and outlet pressure sensor Crankcase pressure sensor EGR orifice temperature sensor Exhaust manifold pressure sensor Coolant temperature sensor Engine oil level sensor *1 Air cleaner clogging sensor KDOC outlet temperature sensor KDPF outlet temperature sensor Common rail pressure sensor Charge (boost) pressure & temperature sensor Ambient pressure sensor Ne (crankshaft) speed sensor Bkup (camshaft) speed sensor Engine oil pressure switch Mass air flow and temperature sensor EGR valve lift sensor Water-in-fuel sensor

Connector label name VGT_REV SVGT TEMP1 PDPF PCCV C22 C26 C3 AF1 TEMP2 TEMP3 C21 C14 C31 C19 C15 OIL PRESSURE SWITCH MAF SEGR WIF1

*1: The installation depends on the machine model.

10-98

114E-5 SERIES

10 Structure and function Sensor

KVGT speed sensor

(ENG-AAQ4-041-K-00-A)

KVGT: Abbreviation for KOMATSU Variable Geometry Turbocharger

1. Sensor 2. O-ring 3. Connector

Function

(ENG-AAQ4-042-K-00-A)

• This sensor, installed to KVGT in the engine, outputs the pulse voltage due to the rotation of KVGT turbine. a The 3-pole connector is applied for this sensor, however, available pins are the pin No. 1 and No. 2 only, and it has no pin No. 3.

114E-5 SERIES

10-99

10 Structure and function Sensor

KVGT position sensor

(ENG-AAQ3-041-K-00-A)

KVGT: Abbreviation for KOMATSU Variable Geometry Turbocharger

1. O-ring (small) 2. O-ring (large) 3. Sensor 4. Connector

Function

(ENG-AAQ3-042-K-00-A)

• This sensor, installed to KVGT in the engine, detects the location of the nozzle ring which is built in KVGT to output the corresponding variable voltage.

Output characteristics • The relation between stroke and output voltage is as shown in the following graph.

10-100

114E-5 SERIES

10 Structure and function Sensor

KDOC inlet temperature sensor

(ENG-A9HG-041-K-00-A)

KDOC: Abbreviation for KOMATSU Diesel Oxidation Catalyst

1. Sensor 2. Connector

Function

(ENG-A9HG-042-K-00-A)

• This sensor, installed to the inlet side of KDOC which is built in KDPF, converts the temperature variation into the resistance variation, and outputs the corresponding signals.

114E-5 SERIES

10-101

10 Structure and function Sensor

KDPF differential pressure and outlet pressure sensor

(ENG-A9HL-041-K-00-A)

KDPF: Abbreviation for KOMATSU Diesel Particulate Filter

1. High-pressure port 2. Low-pressure port 3. Connector 4. Sensor

Function

(ENG-A9HL-042-K-00-A)

• This sensor, installed to KDPF, detects the inlet pressure and outlet pressure of KDPF to output the corresponding variable voltage.

• The output pressure difference is the difference between the KDPF inlet pressure which is detected at high-pressure port (1) and the KDPF outlet pressure which is detected at low-pressure port (2).

• The KDPF outlet pressure is output as a pressure which is detected at low-pressure port (2).

Crankcase pressure sensor

(ENG-A18C-041-K-00-A)

1. Connector 2. Sensor 3. O-ring

Function

(ENG-A18C-042-K-00-A)

• This sensor, installed to the inlet side of KCCV head portion, detects the crankcase pressure (blowby pressure) to output the corresponding variable voltage.

10-102

114E-5 SERIES

10 Structure and function Sensor

EGR orifice temperature sensor

(ENG-A9U5-041-K-00-A)

EGR: Abbreviation for Exhaust Gas Recirculation

1. Connector 2. Sensor 3. Washer

Function

(ENG-A9U5-042-K-00-A)

• This sensor, installed on the EGR gas piping between EGR cooler and EGR valve of the engine, converts the temperature variation into the resistance variation, and outputs the corresponding signals.

Exhaust manifold pressure sensor

(ENG-AAN5-041-K-00-A)

1. O-ring 2. Sensor 3. Connector

Function

(ENG-AAN5-042-K-00-A)

• This sensor, installed to the pressure outlet tube installed to the exhaust manifold of the engine, detects the exhaust pressure to output the corresponding variable voltage.

114E-5 SERIES

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10 Structure and function Sensor

Coolant temperature sensor

(ENG-BA87-041-K-00-A)

1. Connector 2. Sensor 3. O-ring

Function

(ENG114-BA87-042-K-00-A)

• This sensor, installed on the cylinder head of the engine, converts the temperature variation into the resistance variation, and outputs the corresponding signals.

Engine oil level sensor

(ENG-AB45-041-K-00-A)

1. Connector 2. Bracket 3. Float 4. Switch

Function

(ENG-AB45-042-K-00-A)

• This sensor, installed on the side face of the oil pan, turns "OFF" by the lowered float, if the oil level becomes lower than specified.

10-104

114E-5 SERIES

10 Structure and function Sensor

Air cleaner clogging sensor

(PC-A968-041-K-01-A)

1. Adapter 2. Hood 3. Indicator 4. Connector

Function

(PC-A968-042-K-00-A)

• This sensor is installed on the air cleaner outlet side. The switch is turned to "ON" position, if the air cleaner is clogged and the pressure level drops to the specified level (negative pressure).

114E-5 SERIES

10-105

10 Structure and function Sensor

KDOC outlet temperature sensor

(ENG-A9HH-041-K-00-A)

KDOC: Abbreviation for KOMATSU Diesel Oxidation Catalyst

1. Sensor 2. Connector

Function

(ENG-A9HH-042-K-00-A)

• This sensor, installed to the outlet side of KDOC which is built in KDPF, converts the temperature variation into the resistance variation, and outputs the corresponding signals.

KDPF outlet temperature sensor

(ENG-A9HJ-041-K-00-A)

KDPF: Abbreviation for KOMATSU Diesel Particulate Filter

1. Sensor 2. Connector

Function

(ENG-A9HJ-042-K-00-A)

• This sensor, installed to the outlet side of KDPF, converts the temperature variation into the resistance variation, and outputs the corresponding signals.

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10 Structure and function Sensor

Common rail pressure sensor

(ENG114-AE28-041-K-00-A)

1. Sensor 2. Connector

Function

(ENG-AE28-042-K-00-A)

• This sensor, installed to the common rail in the engine, detects the fuel pressure to output the corresponding variable voltage.

114E-5 SERIES

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10 Structure and function Sensor

Charge (boost) pressure and temperature sensor

(ENG-AAM7-041-K-00-A)

1. Connector 2. Sensor 3. O-ring

Function

(ENG-AAM7-042-K-00-A)

• This sensor is installed to the engine intake manifold. It detects the engine intake air pressure and its temperature, and outputs signals as a variable voltage for pressure, and as variable resistance for temperature. a "Charge pressure and temperature" are the engine intake air pressure and temperature of a turbocharged engine. These are also referred to as "boost pressure and temperature" or "intake air pressure and temperature".

Output characteristics

10-108

114E-5 SERIES

10 Structure and function Sensor

Ambient pressure sensor

(ENG-AAP2-041-K-00-A)

1. Connector 2. Sensor

Function

(ENG-AAP2-042-K-00-A)

• This sensor, installed to the air intake cover at the engine top side, detects the ambient pressure to output the corresponding variable voltage.

Output characteristics

114E-5 SERIES

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10 Structure and function Sensor

Ne (crankshaft) speed sensor

(ENG114-AG42-041-K-00-A)

1. O-ring 2. Sensor 3. Connector

Function

(ENG114-AG42-042-K-00-A)

• This sensor, installed to the rear left side of the engine cylinder block, outputs the pulse voltage due to the gear rotation.

10-110

114E-5 SERIES

10 Structure and function Sensor

Bkup (camshaft) speed sensor

(ENG-AG62-041-K-00-A)

1. O-ring 2. Sensor 3. Connector

Function

(ENG114-AG62-042-K-00-A)

• This sensor, installed to the ring of cam shaft on the engine front cover, outputs the pulse voltage due to the gear rotation.

114E-5 SERIES

10-111

10 Structure and function Sensor

Engine oil pressure switch

(ENG114-ABK6-041-K-00-A)

1. Connector 2. Sensor 3. O-ring

Specifications

(PC220-ABK6-030-K-00-A)

Contact type: Normally closed

Function

(ENG114-ABK6-042-K-00-A)

• This oil pressure switch is installed to the cylinder block. It detects engine oil pressure, and turns the switch to "ON" position when the pressure goes below the specified value.

10-112

114E-5 SERIES

10 Structure and function Sensor

Mass air flow and temperature sensor

(ENG-A96H-041-K-00-A)

1. Connector 2. O-ring 3. Sensor

Function

(ENG-A96H-042-K-00-A)

• This sensor is installed to the outlet side of air cleaner, converts the variations of intake air flow and temperature into the resistance variation, and outputs the corresponding signals. a The "MAF (Mass Air Flow)" means the "intake air flow".

114E-5 SERIES

10-113

10 Structure and function Sensor

EGR valve lift sensor

(ENG-A9S2-041-K-00-A)

EGR: Abbreviation for Exhaust Gas Recirculation

1. O-ring (small) 2. O-ring (large) 3. Sensor 4. Connector

Function

(ENG-A9S2-042-K-00-A)

• This sensor, installed to EGR valve in the engine, detects the EGR valve opening to output the corresponding variable voltage.

Output characteristics • The relation between stroke and output voltage is as shown in the following graph.

10-114

114E-5 SERIES

10 Structure and function Sensor

Water-in-fuel sensor

(PC-AEB3-041-K-00-A)

1. Connector 2. Tube 3. Sensor 4. O-ring

Function

(PC-AEB3-042-K-00-A)

• This sensor is installed to the cup of fuel prefilter.

• This sensor outputs a signal when detecting water exists in the fuel beyond the specified level.

114E-5 SERIES

10-115

10-116

114E-5 SERIES

SHOP MANUAL

ENGINE 114E–5 SERIES Model

Serial Number

114E–5 SERIES

20 Standard value tables 4 20 Standard value tables

114E-5 SERIES

20-1

20 Standard value tables Table of contents

Table of contents

(ALL-0310-002-A-00-A)

20 Standard value tables.................................................................................................................... 20-1 Table of contents ........................................................................................................................ 20-2 Standard service value table........................................................................................................ 20-3 Standard value table for engine ............................................................................................. 20-3 Running-in standard and performance test standard ............................................................... 20-9

20-2

114E-5 SERIES

20 Standard value tables Standard value table for engine

Standard service value table

(ALL-A000-001-K-00-A)

Standard value table for engine

(ENG107-A000-033-K-00-A)

Applicable machines: D65EX-17, D65PX-17, D65WX-17 Engine Item

Measurement condition

Unit

(ENG114-A000-033-K-01-A)

SAA6D114E-5 Standard value Repair limit for new machine

Performance Max. speed with no load Min. speed with no load Necessary speed for (at 0°C) starting (at -20°C)

rpm rpm rpm rpm

2,100 ± 50 825 ± 25 – 80

2,100 ± 50 825 ± 25 – –

Max. 3.73 {380}

7.45 {760}

120 to 160 {900 to 1,200}

93 {700}

°C

Max. 650

Max. 700

Engine outlet (between turbocharger and KDPF inlet)

Bosch index

Max. 1.2

Max. 1.5

KDPF outlet (Exhaust pipe outlet)

Bosch index

–

Max. 0.5

0.305 0.559

0.152 to 0.559 0.381 to 0.813

Min. 1.2 {12.2}

Min. 1.2 {12.2}

Min. 1.2 {12.2}

Min. 1.2 {12.2}

Min. 2.6 {26.5}

2.1 {21.4}

Engine speed

Air intake and exhaust system kPa {mmH2O} kPa {mmHg}

Air intake resistance Whole speed range Boost pressure (aftercooler inlet) Exhaust temperature (Turbine outlet)

Exhaust gas color

Valve clearance

At rated horsepower Whole speed range (20°C) • Engine coolant temperature: Within operating range • Relieve the arm circuit at the arm IN stroke end, and set swing lock ON • After keeping for 5 seconds in normal condition Intake valve Exhaust valve

EGR valve drive oil pressure

At low idle

KVGT drive oil pressure

At low idle

Main body Compression pressure Blowby pressure

114E-5 SERIES

Engine oil temperature: 40 to 60°C Engine speed: 250 to 280 rpm At rated horsepower (when KCCV is disconnected)

mm mm MPa {kg/cm2} MPa {kg/cm2}

MPa {kg/cm2} kPa {mmH2O}

Max. 1.96 {200} Max. 2.94 {300}

20-3

20 Standard value tables Standard value table for engine

Engine Item

Measurement condition

Unit

SAA6D114E-5 Standard value Repair limit for new machine

Lubrication system

Hydraulic system

Oil temperature Oil consumption

At rated horsepower Engine oil SAE15W-40 temperature: Min. 80° C At low idle Engine oil SAE15W-40 temperature: Min. 80° C Whole speed range (inside oil pan) At continuous rated horsepower (Ratio to fuel consumption)

MPa {kg/cm2}

0.34 to 0.59 {3.5 to 6.0}

0.21 {2.1}

MPa {kg/cm2}

Min. 0.15 {1.5}

Min. 0.08 {0.8}

°C

80 to 110

Max. 120

%

Max. 0.15

Max. 0.3

–

–

– Automatic adjustment (Auto-tensioner)

–

15 to 18

–

Cooling system Radiator pressure valve Fan speed

Cracking pressure (Differential pressure) At rated speed

Belt tension

Between alternator belt Deflection and crankshaft pulley when pressed with Between air finger force of compressor and 98 N {10 kg} crankshaft pulley

20-4

kPa {kg/cm2} rpm

mm

–

114E-5 SERIES

20 Standard value tables Standard value table for engine

Applicable machines: PC360LC-10

(ENG114-A000-033-K-02-A)

Engine Item

Measurement condition

Unit

SAA6D114E-5 Standard value Repair limit for new machine

Performance Max. speed with no load Min. speed with no load Necessary speed for (at 0°C) starting (at -20°C) Engine speed

rpm rpm rpm rpm

2,050 ± 50 1,000 ± 25 – –

2,050 ± 50 1,000 ± 25 – –

Air intake and exhaust system kPa {mmH2O} kPa {mmHg}

Max. 3.73 {380}

7.45 {760}

167 to 207 {1,250 to 1,550}

133 {1,000}

°C

–

–

Engine outlet (between turbocharger and KDPF inlet)

Bosch index

Max. 2.0

Max. 2.5

KDPF outlet (Exhaust pipe outlet)

Bosch index

–

Max. 0.5

0.305 0.559

0.152 to 0.559 0.381 to 0.813

Min. 1.2 {12.2}

Min. 1.2 {12.2}

Min. 1.2 {12.2}

Min. 1.2 {12.2}

Min. 1.2 {12.2}

Min. 1.2 {12.2}

Air intake resistance Whole speed range Boost pressure (aftercooler inlet) Exhaust temperature (Turbine outlet)

Exhaust gas color

Valve clearance

At rated horsepower Whole speed range (20°C) • Engine coolant temperature: Within operating range • Relieve the arm circuit at the arm IN stroke end, and set swing lock ON • After keeping for 5 seconds in normal condition Intake valve Exhaust valve

EGR valve drive oil pressure

At rated horsepower

KVGT drive oil pressure

At rated horsepower

Main body Compression pressure Blowby pressure

114E-5 SERIES

Engine oil temperature: 40 to 60°C Engine speed: 250 to 280 rpm At rated horsepower (when KCCV is disconnected)

mm mm MPa {kg/cm2} MPa {kg/cm2}

MPa {kg/cm2} kPa {mmH2O}

Max. 1.57 {160} Max. 2.55 {260}

20-5

20 Standard value tables Standard value table for engine

Engine Item

Measurement condition

Unit

SAA6D114E-5 Standard value Repair limit for new machine

Lubrication system

Hydraulic system

Oil temperature Oil consumption

At rated horsepower Engine oil SAE15W-40 temperature: Min. 80° C At low idle Engine oil SAE15W-40 temperature: Min. 80° C Whole speed range (inside oil pan) At continuous rated horsepower ‘Ratio to fuel consumption)

MPa {kg/cm2}

0.34 to 0.59 {3.5 to 6.0}

0.21 {2.1}

MPa {kg/cm2}

Min. 0.15 {1.5}

Min. 0.08 {0.8}

°C

80 to 110

Max. 120

%

Max. 0.15

Max. 0.3

–

–

Cooling system Radiator pressure valve Fan speed

Cracking pressure (Differential pressure) At rated speed

Belt tension

Deflection when pressed with finger force of 98 N {10 kg}

20-6

kPa {kg/cm2} rpm mm

– – Automatic Automatic adjustment adjustment (Auto-tensioner) (Auto-tensioner)

114E-5 SERIES

20 Standard value tables Standard value table for engine

Applicable machines: HB335-1, HB335LC-1, HB365-1, HB365LC-1

(ENG114-A000-033-K-

06-A)

Engine Item

SAA6D114E-5 Standard value Repair limit for new machine

Measurement condition

Unit

High idle Engine water temperature: 75 to 85° Low idle C Rated speed

rpm rpm rpm

2,050 ± 30 700 ± 25 1,950

2,050 ± 30 700 ± 25 1,950

kPa {mmHg}

120 to 160 {900 to 1,200}

Max. 93 {700}

Bosch index

Max. 2.5

Max. 3.0

Bosch index mm

– 0.305

Max. 1.0 0.152 to 0.559

mm

0.559

0.381 to 0.813

MPa {kg/cm2}

Min. 2.6 {26.5}

Min. 2.1 {21.4}

kPa {mmH2O}

Max. 1.57 {160} Max. 2.55 {260}

Performance Engine speed

Air intake and exhaust system • Engine water temperature: 75 to 85°C • Hydraulic oil temperature: 45 to Boost pressure 55°C (aftercooler inlet) • Swing lock ON • Arm IN relief + One-touch power maximizing ON Sudden Engine water Exhaust gas color temperature: 75 to 85° acceleration High idle C Intake valve Coolant temperature: Valve clearance Exhaust Normal temperature valve Main body Compression pressure

Blowby pressure

• Engine oil temperature: 40 to 60°C • Engine speed: Min. 170 rpm • Engine water temperature: 75 to 85°C • Hydraulic oil temperature: 45 to 55°C • Arm IN relief + One-touch power maximizing ON

Lubrication system Hydraulic system

KVGT drive oil pressure

KVGT control oil pressure

Oil temperature

114E-5 SERIES

• Engine water temperature: 75 to 85°C • SAE15W-40 • Engine water temperature: 75 to 85°C • Hydraulic oil temperature: 45 to 55°C

At rated horsepower Low idle Low idle

Within oil pressure fluctuation range in whole speed range Whole speed range (inside oil pan)

MPa {kg/cm2} MPa {kg/cm2} MPa {kg/cm2}

0.34 to 0.59 {3.5 to 6.0}

Min. 0.21 {2.1}

Min. 0.15 {1.5}

Min. 0.08 {0.8}

Min. 1.2 {12.2}

Min. 1.2 {12.2}

MPa {kg/cm2}

0.3 to 1.0 {3.1 to 10.2}

0.3 to 1.0 {3.1 to 10.2}

°C

80 to 110

Max. 120

20-7

20 Standard value tables Standard value table for engine

Engine Item

Measurement condition

Unit

SAA6D114E-5 Standard value Repair limit for new machine

Cooling system Fan belt tension

Air conditioner compressor belt tension

20-8

Between fan pulley and alternator pulley Deflection when pressed with finger force of 98 N {10 kg} Between compressor pulley and fan pulley Deflection when pressed with finger force of 60 N {6.2 kg}

mm

mm

Automatic Automatic adjustment adjustment (Auto-tensioner) (Auto-tensioner)

11 to 13

11 to 13

114E-5 SERIES

20 Standard value tables Running-in standard and performance test standard

Running-in standard and performance test standard Applicable machines: D65EX-17, D65PX-17, D65WX-17

(ENG114-A000-034-K-00-A) (ENG114-A000-034-K-01-A)

Running-in standard Engine

min. rpm

1 2 825

2 10 1,000

SAA6D114E-5 Procedure 3 2 1,200

N {kg}

0 {0}

98 {10}

245 {25}

637 {65}

1,118 {114}

kW {HP}

0 {0}

7.4 {9.86}

22 {29.5}

76 {103}

163.7 {219}

Item Running time Engine speed Dynamometer load Output

4 3 1,600

5 10 1,950

a The loads for the dynamometer in this table shows the value when the dynamometer arm is 716 mm long.

Performance test standard Engine Rated horsepower

Max. torque

Max. speed with no load

Min. speed with no load

-

163.7 kW/1,950 rpm {219 HP/1,950 rpm}

1,050 Nm/1,450 rpm {107.1 kgm/1,450 rpm}

2,100 rpm

825 rpm

rpm

1,950

1,450

2,100

825

1,118 {114}

1,472 {150}

–

–

163.7 {219}

–

–

–

-

1,050 {107.1}

–

–

-

–

–

–

69 to 81

69 to 81

69 to 81

69 to 81

80 to 110

80 to 110

80 to 110

80 to 110

0.34 to 0.59 {3.5 to 6.0}

–

–

Min. 0.15 {Min. 1.5}

Max. 600

Max. 650

–

–

Test item Specification value (Gross value) Engine speed

SAA6D114E-5

N Dynamometer load {kg} Output kW (Gross {HP} value) Torque Nm (Gross {kgm} value) Fuel sec/300 consumpcc tion Coolant tempera°C ture Lubricating oil °C temperature Lubricating MPa oil 2} {kg/cm pressure Exhaust tempera°C ture

a This table shows the standard values obtained by using the JIS correction coefficients. a This table shows the standard values when the air cleaner and the KDPF are installed and no load is applied to the alternator. a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long. a Use ATSM D975 diesel oil as the fuel. a Use SAE15W-40 as lubricating oil.

114E-5 SERIES

20-9

20 Standard value tables Running-in standard and performance test standard

Applicable machines: PC360LC-10

(ENG114-A000-034-K-02-A)

Running-in standard Engine

min. rpm

1 2 1,000

2 10 1,000

SAA6D114E-5 Procedure 3 2 1,200

N {kg}

0 {0}

98 {10}

245 {25}

637 {65}

1,384 {141}

kW {HP}

0 {0}

7.4 {9.86}

22 {29.5}

76 {103}

202 {271}

Item Running time Engine speed Dynamometer load Output

4 3 1,600

5 10 1,950

a This table shows the values when the fan is not installed. a The loads for the dynamometer in this table shows the value when the dynamometer arm is 716 mm long.

Performance test standard Engine Rated horsepower

Max. torque

Max. speed with no load

Min. speed with no load

-

202 kW/1,950 rpm {271 HP/1,950 rpm}

1,171 Nm/1,450 rpm {119 kgm/1,450 rpm}

2,050 rpm

1,000 rpm

rpm

1,950

1,450

2,050

825

1,383 {141}

1,635 {167}

–

–

202 {271}

–

–

–

-

1,171 {119}

–

–

20

–

–

–

83 to 95

83 to 95

83 to 95

83 to 95

80 to 110

80 to 110

80 to 110

80 to 110

0.34 to 0.59 {3.5 to 6.0}

–

–

Min. 0.15 {Min. 1.5}

Max. 700

Max. 750

–

–

Test item Specification value (Gross value) Engine speed

SAA6D114E-5

N Dynamometer load {kg} Output kW (Gross {HP} value) Torque Nm (Gross {kgm} value) Fuel sec/300 consumpcc tion Coolant tempera°C ture Lubricating oil °C temperature Lubricating MPa oil 2 pressure {kg/cm } Exhaust tempera°C ture

a This table shows the standard values obtained by using the JIS correction coefficients. a This table shows the standard values when the air cleaner and the KDPF are installed and no load is applied to the alternator. a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long. a Use ATSM D975 diesel oil as the fuel. a Use SAE15W-40 as lubricating oil.

20-10

114E-5 SERIES

20 Standard value tables Running-in standard and performance test standard

Applicable machines: HB335-1, HB335LC-1, HB365-1, HB365LC-1

(ENG114-A000-034-K-

06-A)

Running-in standard Engine Item

1

2

SAA6D114E-5 Procedure 3

4

5

Running time

min.

2

10

2

3

10

Engine speed

rpm

700

700

1,200

1,600

1,950

Dynamometer load Output

N {kg}

0 {0}

98 {10}

245 {25}

637 {65}

1,384 {141}

kW {HP}

0 {0}

7.4 {9.86}

22 {29.5}

76 {103}

202 {271}

a The loads for the dynamometer in this table shows the value when the dynamometer arm is 716 mm long.

Performance test standard Engine Rated horsepower

Max. torque

Max. speed with no load

Min. speed with no load

-

202 kW/1,950 rpm {271 HP/1,950 rpm}

1,171 Nm/1,450 rpm {119 kgm/1,450 rpm}

2,050 rpm

700 rpm

rpm

1,950

1,450

2,050

700

1,383 {141}

1,635 {167}

–

–

202 {271}

–

–

–

-

1,171 {119}

–

–

20

–

–

–

83 to 95

83 to 95

83 to 95

83 to 95

80 to 110

80 to 110

80 to 110

80 to 110

0.34 to 0.59 {3.5 to 6.0}

–

–

Min. 0.15 {Min. 1.5}

Max. 700

Max. 750

–

–

Test item Specification value (Gross value) Engine speed

SAA6D114E-5

N Dynamometer load {kg} Output kW (Gross {HP} value) Torque Nm (Gross {kgm} value) Fuel sec/300 consumpcc tion Coolant tempera°C ture Lubricating oil °C temperature Lubricating MPa oil 2 pressure {kg/cm } Exhaust tempera°C ture

a This table shows the standard values obtained by using the JIS correction coefficients. a This table shows the standard values when the air cleaner and the muffler are installed and no load is applied to the alternator. a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long. a Use ATSM D975 diesel oil as the fuel. a Use SAE15W-40 as lubricating oil.

114E-5 SERIES

20-11

20 Standard value tables Running-in standard and performance test standard

20-12

114E-5 SERIES

SHOP MANUAL

ENGINE 114E–5 SERIES Model

Serial Number

114E–5 SERIES

50 Disassembly and assembly 5 50 Disassembly and assembly

114E-5 SERIES

50-1

50 Disassembly and assembly Table of contents

Table of contents

(ALL-0310-002-A-00-A)

50 Disassembly and assembly ........................................................................................................... 50-1 Table of contents ........................................................................................................................ 50-2 Related information on disassembly and assembly ........................................................................ 50-3 How to read this manual ....................................................................................................... 50-3 Coating materials list ............................................................................................................ 50-5 Special tool list..................................................................................................................... 50-9 Sketch of special tool.......................................................................................................... 50-11 Disassembly and assembly ....................................................................................................... 50-12 General disassembly of engine ........................................................................................... 50-12 General assembly of engine................................................................................................ 50-31 Removal and installation procedure of supply pump unit alone............................................... 50-70 Engine front oil seal replacement procedure ......................................................................... 50-74 Engine rear oil seal replacement procedure.......................................................................... 50-77

50-2

114E-5 SERIES

50 Disassembly and assembly Related information on disassembly and assembly

Related information on disassembly and assembly How to read this manual

(ALL-3851-001-A-00-A)

(ALL-0320-011-A-00-A)

(Rev.2013.05) Removal and installation of TTTT assembly Special tools • The special tools required for removal and installation work are described in the list as symbols such as A1, ..., X1. Part number, part name, necessity, and quantity are described.

• Mark used in the column of necessity are explained below. t: Tools are not substituted, must always be equipped (used). q: Tools extremely useful if available or tools that can be substituted with commercially available tools.

• For details and the sketches of the special tools, see "Special tool list" and "Sketches of special tools."

Removal • In "Removal" section, the work procedures, precautions and know-how to do the work, and the amount of oil and coolant to be drained are described.

• The general tools required for "Removal" are listed as [1], [2], ..., without description of part number, part name, and quantity.

• Marks used in "Removal" section are explained below. k:

This mark shows safety-related precautions which must be followed when performing the work.

• The general tools required for "Installation" are listed as [1], [2], ..., without description of part number, part name, and quantity.

• Marks used in "Installation" section are explained below. k:

This mark shows safety-related precautions which must be followed when performing the work.

a : This mark gives knowledge or precautions when performing the work.

4 : This mark shows the weight of the part or equipment.

2 : This mark shows a specific coating agent to be used.

3 : This mark shows the specified tightening torque.

5 : This mark shows the amount of oil or coolant to be added.

• For details of oil or coolant to be added after installation, see Specification "Table of fuel, coolant and lubricants".

Disassembly and assembly of TTTT assembly Special tools

Installation

• The special tools required for disassembly and assembly work are described in the list as symbols such as A1, ..., X1. Part number, part name, necessity, and quantity are described.

• Mark used in the column of necessity are explained below. t: Tools are not substituted, must always be equipped (used). q: Tools extremely useful if available or tools that can be substituted with commercially available tools.

• For details and the sketches of the special tools, see "Special tool list" and "Sketches of special tools."

• The work procedure of "Installation" is in the reversed order to removal unless otherwise specified.

• For knowledge and precautions required for "Installation", a [*1] mark is assigned to the "Removal" work procedure to indicate the work item of the installation knowledge or precaution.

Disassembly • "Disassembly" describes the work procedure as well as the precautions, knowledge, and drain amounts of oil and coolant required for the work.

• The general tools required for "Disassembly" are listed as [1], [2], ..., without description of part number, part name, and quantity.

a : This mark gives knowledge or precautions when performing the work. [*1]: This mark indicates that knowledge or precautions for the assembly installation work are given in the "Installation" section.

6 : This mark shows the amount of oil or coolant to be drained.

4 : This mark shows the weight of the part or equipment.

114E-5 SERIES

50-3

50 Disassembly and assembly Related information on disassembly and assembly

• Marks used in the section of "Disassembly" are explained below. k:

This mark shows safety-related precautions which must be followed when performing the work.

a : This mark gives knowledge or precautions when performing the work.

6 : This mark shows the amount of oil or coolant to be drained.

4 : This mark shows the weight of the part or equipment.

Assembly • "Assembly" describes the work procedure as well as the precautions, knowledge, and drain amounts of oil and water required for the work.

• The general tools required for "Assembly" are listed as [1], [2], ..., without description of part number, part name, and quantity.

• Marks used in the section of "Assembly" are explained below. k:

This mark shows safety-related precautions which must be followed when performing the work.

a : This mark gives knowledge or precautions when performing the work.

4 : This mark shows the weight of the part or equipment.

2 : This mark shows a specific coating agent to be used.

3 : This mark shows the specified tightening torque.

5 : This mark shows the amount of oil or coolant to be added.

• For details of oil or coolant to be added after installation, see Specification "Table of fuel, coolant and lubricants".

50-4

114E-5 SERIES

50 Disassembly and assembly Related information on disassembly and assembly

Coating materials list

(ALL-3540-071-A-00-A)

(Rev.2012.11) a The coating materials such as adhesives, liquid gasket, and grease used for disassembly and assembly are listed below. a For coating materials not listed below, use the equivalent of products shown in this manual.

Adhesive Komatsu code

Part No.

Capacity

Container

LT-1A

790-129-9030

150 g

Tube

LT-1B

790-129-9050

20 g (contained 2 pieces)

Polyethylene container

LT-2

790-129–9180

50 g

Polyethylene container

Main features and applications • Use to prevent rubber gaskets, rubber cushions, and cork plugs from coming out.

• Use for plastic (except polyethylene, polypropylene, tetrafluoroethylene and vinyl chloride), rubber, metal, and nonmetal parts which require immediate and strong adhesion.

• Features: Resistance to heat and chemicals • Use to prevent bolts and plugs from coming loose and as sealant.

LT-3

790-129-9060 Set of adhesive and hardener

Adhesive: 1 kg Hardener: 500 g

Can

• Use to bond and seal metal, glass and plastics.

LT-4

790-129-9040

250 g

Polyethylene container

Holts MH705

790-129-9120

75 g

Tube

ThreeBond 1735

790-129-9140

50 g

Polyethylene container

Aron Alpha 201

790-129-9130

2g (contained 5 pieces)

Polyethylene container

Loctite 499

428-99-80070

20 cc

Tube

Loctite 648-50

79A-129-9110

50 cc

Polyethylene container

114E-5 SERIES

• Use to seal plugs for blank holes.

• Heat-resistant seal used to repair engines • Instantaneous adhesive • Curing time: From 5 sec. to 3 min.

• Use mainly to bond metals, rubbers, plastics, and woods.

• Instantaneous adhesive • Quick-curing type (max. strength is obtained after 30 minutes) • Use mainly to bond rubbers, plastics, and metals.

• General-purpose instantaneous adhesive with excellent resistance to heat and impact • Use on the bushing mounting faces of axle supports.

• Features: Resistance to heat and chemicals • Use to bond high-temperature fit parts.

50-5

50 Disassembly and assembly Related information on disassembly and assembly

Liquid gasket Komatsu code LG-5 ThreeBond 1110F

Part No. 790-129-9080

Capacity

Container

1 kg

Polyethylene container

• • •

LG-6 ThreeBond 1215

790-129-9160

250 g

Tube

• • •

LG-7 ThreeBond 1207C

790-129-9170

150 g

Tube

LG-8 ThreeBond 1207B

419-15-18131

100 g

Tube

LG-9 ThreeBond 1206D

790-129-9310

• • • •

200 g

Tube • •

LG-10 ThreeBond 1206E

790-129-9320

200 g

LG-11 ThreeBond 1121

790-129-9330

200 g

Tube

•

ThreeBond 1211

790-129-9090

100 g

Tube

•

Tube • •

Main features and applications Use to seal various threaded parts, pipe joints, and flanges.

Use to seal taper plugs, elbows, and nipples for hydraulic piping.

Features: Silicon-based heat and coldresistant sealant.

Use to seal flange surface and threaded parts.

Use to seal oil pan, final drive case, etc.

Features: Silicon-based quick-curing sealant Use to seal flywheel housing, intake manifold, oil pan, thermostat housing, etc.

Features: Silicon-based heat, vibration, and shock-resistant sealant.

Use to seal transfer case, etc.

Use for rough surfaces such as the circle gear top seal which is not clamped by bolts, gaps in the weld which must be caulked, etc.

Can be coated with paint.

Use as lubricant or sealant when the radiator hoses are put on.

Can be coated with paint.

Feature: Can be used together with solid gaskets.

Use for covers of the transmission case and steering case etc.

Liquid gasket used to repair engine

Molybdenum disulfide lubricant Komatsu code

Part No.

Capacity

Container

LM-P

09940-00040

200 g

Tube

LM-S

09995-00250

190 g

Can

50-6

Main features and applications • Use to prevent galling and seizure of press-fitted parts, shrinkage-fitted parts, and threaded parts.

• Use to lubricate linkages, bearings, etc.

• Spray type • Thin molybdenum disulfide films are made on metal surfaces to prevent the metals from galling.

• Use for the drive shaft splines, needle bearings, various link pins, bolts, etc.

114E-5 SERIES

50 Disassembly and assembly Related information on disassembly and assembly

Seizure prevention compound Komatsu code

Part No.

Capacity

Container

LC-G NEVER-SEEZ

—

—

Can

Capacity

Container

Various

Various

• Lithium grease with extreme pressure lubrication performance, general purpose type.

400 g x 10 400 g x 20 16 kg

Bellowstype container Can

• Use for parts under heavy load.

Caution: • Do not use this grease for rolling bearings like swing circle bearings, etc. and spline.

• Use this grease for work equipment pins only when installing them, but do not use it afterward.

• Higher seizure resistance, heat resistance, and waterproof than molybdenum disulfide grease • Not conspicuous on machine since color is white.

• Since this grease is biodegradable in short period, it has less impact on microorganisms, animals, and plants.

Main features and applications • Feature: Seizure and galling prevention compound with metallic super-finegrain, etc.

• Use for the mounting bolt in the high temperature area of the exhaust manifold and the turbocharger, etc.

Grease Komatsu code

Part No. SYG2-400LI-A G2-LI SYGA-16CNLI G0-LI(*) SYG0-400LI-A *: For cold districts (*) SYG0-16CNLI (*)

Molybdenum disulfide grease LM-G(G2-M)

SYG2-400M SYG2-400M-A SYGA-16CNM

Hyper white grease G2-T G0-T(*) *: For cold districts Biogrease G2-B G2-BT(*) *: For use at high temperature and under high load

SYG2-400T SYG2-16CNT SYG0-400T(*) SYG0-16CNT(*)

400 g 16 kg

Bellowstype container Can

SYG2-400B SYGA-16CNB SYG2-400BT(*) SYGA-16CNBT (*)

400 g 16 kg

Bellowstype container Can

G2-S ThreeBond 1855

—

200 g

Tube

G2-U-S ENS grease

427-12-11871

2 kg

Can

114E-5 SERIES

Main features and applications

• Feature: Silicon-based grease with wider operating temperature range and superior thermal oxidative stability to prevent deterioration of rubber and plastic.

• Use for oil seals of the transmission, etc.

• Feature: Urea (organic) grease with heat resistance and long life, inclusion type.

• Use for rubber, bearing and oil seal in damper.

Caution: Do not mix with lithium grease.

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50 Disassembly and assembly Related information on disassembly and assembly

Primer Loctite 712

Part No.

Capacity

428-99-80080

100 ml

SUNSTAR Paint Surface Primer 580 SUPER SUNSTAR Glass Primer 580 SUPER

417-926-3910

SUNSTAR Paint Surface Primer 435-95

Container Glass container

20 ml

Glass container

20 ml

Glass container

22M-54-27230

20 ml

Glass container

SUNSTAR PRIMER 435-41 for glass

22M-54-27240

150 ml

Steel can

SUNSTAR sash primer GP-402

22M-54-27250

20 ml

Glass container

Komatsu code

Part No.

Capacity

Container

SUNSTAR Penguin Seal 580 SUPER "S" or "W"

417-926-3910

320 ml

Polyethylene container

Sika Japan Sikaflex 256HV

20Y-54-39850

310 ml

Cartridge

SUNSTAR Penguin Super 560

22M-54-27210

320 ml

Ecocart (special container)

Part No.

Capacity

Container

417-926-3920

330 ml

Cartridge

20Y-54-55130

333 ml

Cartridge

Main features and applications • Use to accelerate hardening of instantaneous adhesive.

• Use as primer for cab side.

(Effective period: 4 months after manufacture) • Use as primer for glass side.

(Effective period: 4 months after manufacture) • Use as primer for painted cab sheet metal surface.

(Effective period: 4 months after manufacture) • Use as primer for black ceramiccoated glass surface and for hard polycarbonate-coated surface.

(Effective period: 4 months after manufacture) • Use as primer for sash (alumite surface treatment).

(Effective period: 4 months after manufacture)

For adhered window glass

Komatsu code

For adhered window glass

Adhesive Main features and applications • Use "S" as adhesive for glass in high temperature months (during summer) and "W" in low temperature months (during winter).

(Effective period: 4 months after manufacture) • Use as adhesive for glass.

(Effective period: 6 months after manufacture) • Use as adhesive for glass.

(Effective period: 6 months after manufacture)

Komatsu code SUNSTAR Penguin Seal No.2505 SEKISUI Silicone Sealant 83 GE TOSHIBA SILICONES TOSSEAL381

50-8

22M-54-27220

333 ml

Cartridge

For adhered window glass

Caulking material Main features and applications • Use to seal glass-to-glass joint.

(Effective period: 4 months after manufacture) • Use to seal front window.

(Effective period: 6 months after manufacture) • Translucent white seal used for joint seals between glasses (Effective period: 12 months after manufacture)

114E-5 SERIES

50 Disassembly and assembly Related information on disassembly and assembly

Special tool list

(ENG114-3530-061-A-00-A)

a Tools with part number 79*T-***-****: are not supplied (to be locally manufactured). a Necessity t: Tools are not substituted, must always be equipped (used). q: Tools extremely useful if available or tools that can be substituted with commercially available tool. a New/redesign N: Tools with new part numbers, newly developed for this model.

R: Tools, with advanced part numbers, developed by improving existing tools for other models.

Blank: Tools already available for other models that can be used without any modification.

A Disassembly and assembly of engine

790-501-2001 795-799-1150

Part name

Repair stand

Adapter

t 1

Spring pusher

q 1

795-799-2280 Removal and installation of air intake valve and exhaust valve Removal and installation of piston ring Installation of piston Removal of injector Angle tightening of bolt

Special for KOMATSU Q repair stand Special for CUMMINS repair stand

795-102-2103 C

795-799-8800

D

795-100-2800

Piston ring tool

t 1

E F

795-921-1100 795-799-6700 790-331-1120 795-799-2240 Commercially available

Piston holder Puller Wrench (angle) Angle gauge

t t q q

Feeler gauge

q 1

Dial gauge stand

q 1

Remover

q 1

Lifting tool

q 1

Remover

q 1

Fuel spray prevention cap pliers

q 1

Liner puller

q 1

Extension

q 1

Cylinder liner driver

q 1

Oil seal driver

q 1

J

Adjustment of valve K clearance Adjustment of Commercially backlash and end play L available of gear Removal of inlet M 795-799-8150 connector Sling for engine N 795-799-9300 assembly Removal and installation of supply P 795-799-1390 pump Removal and Q 795-799-8910 installation of cylinder head valve seal Removal and 1 795-799-2170 installation of cylinder R 2 795-799-2310 liner Installation of cylinder S 795-799-2110 liner Installation of front seal T 795-799-8120

114E-5 SERIES

Detail of work, remarks

t 1

790T-901-6030 B

Sketch

Part No.

Necessity Q'ty New/redesign

Work

Symbol

a Tools marked withQin the Sketch column have the sketches. (See Sketches of special tools)

1 1 1 1

f 75 - 175 mm

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50 Disassembly and assembly

Removal and installation of main bearing Rotating crankshaft Tightening injector wiring harness nut Measuring cylinder head bolt length Installation of cylinder liner

50-10

Part name

U

795-799-2270

Remover, installer

q 1

V

795-799-1131

Gear

q 1

W

795-799-7110

Torque wrench

q 1

X

795-790-2210

Gauge

q 1

Y

795-799-2190

Clamp set

q 1

Sketch

Part No.

Necessity Q'ty New/redesign

Work

Symbol

Related information on disassembly and assembly

Detail of work, remarks

114E-5 SERIES

50 Disassembly and assembly Related information on disassembly and assembly

Sketch of special tool

(ENG114-3531-066-A-00-A)

Note: Komatsu cannot accept any responsibility for special tool manufactured according to this sketch.

B: Adapter

114E-5 SERIES

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50 Disassembly and assembly Disassembly and assembly

Disassembly and assembly General disassembly of engine

(ENG107-A000-001-K-00-A) (ENG114-A000-530-K-00-A)

a This document describes the general disassembly procedure for SAA6D114E-5.

Before starting your work, check the shapes, quantities, locations, etc. of the installed parts since they depend on the machine model.

1. Preparation work Before disassembling the engine, check its parts for cracking, damage, etc. and clean it generally and carefully for accurate inspection of its parts and quick disassembly and assembly. a Before cleaning the engine, carefully seal or remove the openings, electric parts, and wiring connectors so that water does not enter them. a Prepare stable engine stands (blocks [1]) and secure engine assembly (1) on them so that it does not tip over.

5) Disconnect blowby hose (6). a Press lock (L) to pull out the connector.

6) Remove connector (7) at oil filler port inlet.

4 Engine assembly: Approx. 900 kg (Weight depends on the applicable machine model)

3. Fuel filter and hose 1) Disconnect fuel hoses (2) and (3) from fuel filter (1).

2. Oil filler port 1) Disconnect clamp (2) of oil filler port (1).

2) Loosen hose clamp (3) and remove oil filler port (1).

3) Disconnect tube clamp (4).

4) Remove tube (5).

a Removal of fuel hose While pressing the fittings (right and left) at the hose end, pry the hose end face with a screwdriver to disconnect.

2) Disconnect clamp (5) that are bundling fuels hoses (2), (3) and (4).

3) Remove fuel filter (1) and bracket (6) as a unit.

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50 Disassembly and assembly Disassembly and assembly

8) Disconnect wiring harness (2) from engine controller (1). a Wiring harness (2) is locked with hexagonal socket head bolt (10) (4 mm).

9) Disconnect clamp (11) securing wiring harness (2) together with bracket (12).

10)Disconnect clamp (13) securing wiring harness (2).

11)Disconnect clamp (14) securing wiring harness (2).

4) Disconnect tube clamp (7).

5) Disconnect tube (8).

6) 7) 8) 9)

Remove fuel hose (2).

Remove fuel hose (3).

Remove fuel hose (4).

Remove fuel hose (9).

4. Engine controller 1) Disconnect Ne (crankshaft) speed sensor connector (3).

2) Disconnect engine oil pressure switch connector (4).

3) Disconnect fuel lift pump connector (5).

4) Disconnect Bkup (cam) speed sensor connector (6).

5) Remove bolt (7) for wiring harness (2).

6) Disconnect wiring harness (2) from bracket (8).

7) Disconnect clamp (9) for wiring harness (2).

114E-5 SERIES

a Wiring harness (2) is tightened together with the clamp of blowby hose (15).

12)Remove bracket (8) on engine controller (1).

13)Remove bracket (16).

14)Remove engine controller (1). a Ground cable (17) is tightened together with the engine controller mounting bolt.

5. Engine controller cooling plate and fuel lift pump 1) Remove engine controller cooling plate (2) and bracket (1).

2) Remove fuel lift pump (3) on the back side of engine controller cooling plate (2).

3) Remove ground (3) and oil pressure switch connector (4).

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50 Disassembly and assembly Disassembly and assembly

4) Disconnect clamp (11) for wiring harness (10) from bracket (9).

5) Disconnect EGR valve pipe (1) from EGR valve (8). a Take care to prevent the gasket from coming off.

6) Remove wiring harness bracket (9) from EGR valve (8).

7) Remove EGR valve (8).

6. EGR valve 1) Disconnect EGR orifice temperature sensor connector (2) of EGR valve pipe (1).

8) Loosen hose clamp (10) and remove EGR valve pipe (1).

2) Disconnect wiring harness connectors (3), (4) and (5).

• Connector (3): KVGT position sensor • Connector (4): KVGT speed sensor • Connector (5): Connector box 3) Disconnect hoses (6) and (7).

• Hose (6): KVGT control hydraulic circuit • Hose (7): KVGT drive hydraulic circuit

50-14

7. Wiring harness assembly Disconnect the connector, clamp and band, and remove the wiring harnesses assembly.

• Coolant temperature sensor connector (2)

114E-5 SERIES

50 Disassembly and assembly Disassembly and assembly

• • • •

Supply pump connector (15) Wiring harness connectors (16): three places Wiring harness clamp (17) Band (18)

• Exhaust manifold pressure sensor connector (3) • Wiring harness clamp (4) • Charge (boost) pressure and temperature sensor connector (19) • Common rail pressure sensor connector (20) • Wiring harness clamp (21) • Wiring harness bracket (22)

• Bands (5), (8) and (9) • Wiring harness clamps (6), (7) and (10)

8. Intake manifold 1) Disconnect sandwich clamp (2) from highpressure pipe (3) of intake manifold (1). a Remove sandwich clamp (2) together with high-pressure pipe (3).

• Wiring harness clamps (11), (12) and (13)

2) Disconnect clamp (4) for supply pump connector (5) from intake manifold (1).

3) Remove intake manifold (1).

• Ambient pressure sensor connector (14) 114E-5 SERIES

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50 Disassembly and assembly Disassembly and assembly

9. Blowby hose Remove blowby hose (1).

11.Tubes and hoses 1) Disconnect hose (1) and tube (2) at portion (A).

2) Disconnect tube clamp (3).

3) Loosen hose clamp (4) and remove tube (2).

4) Remove tube (5).

10.Installation to engine repair stand 1) Remove dipstick pipe (1). a The shape depends on the applicable machine model.

5) Remove tube (6) and bracket (7).

6) Disconnect tub clamp (8) and remove tube (9).

7) Disconnect hoses (10) and (11) from EGR cooler (12).

2) Install tool B to engine assembly (2).

3) Sling engine assembly (2) and install it to tool A repair stand.

4 Engine assembly: Approx. 880 kg (Weight depends on the applicable machine model) 4) Drain the engine coolant and engine oil.

8) Disconnect hose (14) from KVGT (13).

9) Remove bracket (16) from exhaust manifold (15) together with connector block (17) and hoses (10), (11) and (14).

6 Engine oil: Approx. 24 l

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114E-5 SERIES

50 Disassembly and assembly Disassembly and assembly

12.KVGT 1) Loosen hose clamp (1) and disconnect tube (2).

2) Disconnect tube (3).

14.Alternator belt Remove alternator belt (1). a Attach a wrench to portion (A) (width across flats: 12.7 mm) of tensioner assembly (2), and rotate the wrench in the direction opposite to the winding-up direction to decrease alternator belt (1) tension. k Rotate

the wrench after making sure it is securely attached to portion (A) of tensioner assembly (2). (If you try to rotate the wrench before it is securely attached due to the strong spring force of tensioner assembly (2), it can disengage and cause serious physical injuries.)

3) Lift off KVGT (4).

4 KVGT: 30 kg

13.Starting motor assembly Remove mounting bolt (2) and nut (3), and remove starting motor assembly (1).

k After

removing alternator belt (1), return tensioner assembly (2) slowly and carefully.

k Take

care not to get your fingers caught between the pulley and alternator belt (1) during work.

15.Alternator 1) Remove alternator (1).

2) Remove brackets (2) and (3).

114E-5 SERIES

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50 Disassembly and assembly Disassembly and assembly

16.Pulley and lifting plate

2) Remove thermostat (1).

1) Remove pulley (1) and wiring harness brackets (2) and (3).

2) Remove plate (4).

19.Coolant inlet connector 1) Remove coolant inlet connector (1).

2) Remove plug (2).

17.Belt tensioner Remove belt tensioner (1).

20.Water pump Remove water pump (1).

18.Thermostat 1) Remove coolant outlet connector (2). a The shape depends on the applicable machine model.

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114E-5 SERIES

50 Disassembly and assembly Disassembly and assembly

21.Oil filter and oil cooler a Before removing the oil filter and oil cooler, place an oil container under them.

1) Remove oil filter (1).

23.Exhaust manifold 1) Remove bracket (1).

2) Remove exhaust manifold (2).

2) Remove bolt (6), and remove cover (2) and cover gasket (3).

3) Remove oil cooler (4) and cooler gasket (5).

a Take care to prevent the gasket from coming off when disconnecting the above.

24.Head cover and rocker housing 22.EGR cooler 1) Remove mounting bolt (1), then separate EGR cooler (2) from exhaust manifold (3).

1) Remove head cover (1).

a Take care to prevent the gasket from falling when disconnecting the above.

2) Remove tube (4) below the EGR cooler.

3) Remove EGR cooler (2).

4) Remove tube (5).

2) Disconnect wiring harness (2) from the injector. a Locations of wiring harnesses

5) Remove bracket (6).

6) Remove plugs (7) and (8).

114E-5 SERIES

Color of cable a Yellow Orange b c Red d Brown

Cylinder No. Right side 1, 3, 5 Left side Right side 2, 4, 6 Left side

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50 Disassembly and assembly Disassembly and assembly

3) Remove mounting bolt (3) and remove rocker housing (4).

25.High-pressure pipe 1) Remove 14 fuel spray prevention caps (8) of high-pressure pipes (1) to (7).

2) Loosen sandwich clamp (9) of high-pressure pipes (1) to (7).

3) Loosen the sleeve nut of common rail side for high-pressure pipes (1) to (7).

4) Loosen the sleeve nut of injector side for high-pressure pipes (1) to (7).

5) Remove the bolt of sandwich clamp (9) mounting bracket for high-pressure pipes (1) to (7).

6) Remove high-pressure pipes (1) to (7).

7) Disconnect tube (10).

8) Disconnect tube (11).

9) Disconnect tube clamp (12).

10)Remove tube (13).

26.Supply pump 1) Remove cap (1) of the front gear cover.

2) Remove nut (2) and washer (3).

a Remove high-pressure pipes together with the sandwich clamp mounting bracket.

3) After removing the washer, tighten nut (2) again.

4) Rotate the crankshaft in the normal direction to set stamp (a) of supply pump drive gear (4) to the top, and set the No. 1 cylinder to the compression top dead center (TDC).

50-20

114E-5 SERIES

50 Disassembly and assembly Disassembly and assembly

5) Install tool P to the front gear cover using bolt [1] (M8 x 1.25).

6) Remove four nuts (5) and bolts (6) and (7), and remove bracket (8).

7) Alternately tighten bolts [1] of tool P, which is installed in Step 5, and disconnect the supply pump drive shaft from the supply pump drive gear.

8) Remove tool P, then remove supply pump (9).

28.Common rail and connector block 1) Remove mounting bolts (1) and (2), and remove common rail (3).

2) Remove wiring harness bracket (4).

3) Remove connector block (5).

29.Rocker arm and crosshead 1) Remove 12 mounting bolts (1), and remove rocker arm assembly (2).

27.Boost pump 1) Disconnect hose (1) from cylinder block (2).

2) Remove two bolts (3) and remove boost pump (4).

114E-5 SERIES

a Loosen lock nut (4), then loosen adjustment screw (5) a few turns so that the tension of the valve spring is not applied to rocker arm mounting bolts (1).

2) Remove crosshead (3).

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50 Disassembly and assembly Disassembly and assembly

a Record the positions and shapes of holes (a) and (b).

2) Remove bolt (3) and remove holder (4).

3) Using tool F, pull up injector (5).

30.Push rod Remove 12 push rods (1).

a Do not pry up the injector top.

31.Injector assembly a Before removing the inlet connector, remove all mud, etc. sticking around it so that mud, etc. does not enter the hole of the connector.

1) Remove retaining nuts (1) and remove six inlet connectors (2). a Use tool M to remove the inlet connectors.

32.Intake manifold cover Remove intake manifold cover (1).

50-22

114E-5 SERIES

50 Disassembly and assembly Disassembly and assembly

a Remove bracket (2) which is tightened together with the cover.

2] Remove upper seat (5) and valve spring (3).

33.Cylinder head assembly 1) Remove the 26 bolts (1) and remove cylinder head assembly (2).

3] Place the cylinder head assembly sideways and pull out valve (6).

4 Cylinder head assembly: 95 kg

2) Disassemble the cylinder head according to the following procedure.

1] Using tool C, compress valve spring (3) to remove valve collet (4).

114E-5 SERIES

a Apply a marking to valve (6) so that later you are able to identify which cylinder head it should be combined.

4] Remove valve seals (7-1) and (7-2) on the upper side of the head.

• Exhaust Valve: (7-1) • Intake Valve: (7-2) • Use tool Q to remove the valve seals.

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50 Disassembly and assembly Disassembly and assembly

34.Front cover 1) Remove vibration damper (1).

2) Remove 26 mounting bolts (2) and remove front cover (3).

3) Remove the front oil seal according to the following procedure.

1] Remove dust seal (6) from front oil seal carrier assembly (4).

2] Remove front oil seal carrier assembly (4) from front cover (3).

3] Remove front oil seal (5).

35.Supply pump drive gear Remove supply pump drive gear (1).

36.Oil pump

50-24

114E-5 SERIES

50 Disassembly and assembly Disassembly and assembly

Remove four bolts (1) and oil pump assembly (2).

1) Remove bolt (3) and remove thrust plate (4).

37.Oil pan a Set oil pan upward.

1) Remove 32 bolts (1) and remove oil pan (2).

2) Remove camshaft gear assembly (1) by turning it.

2) Remove suction tube (3), bracket (4) and bed plate (5).

39.Gear housing Remove five bolts (1) and remove gear housing (2).

38.Camshaft a Rotate the crankshaft, and align the mark of camshaft gear assembly (1) with the mark of crankshaft gear (2).

114E-5 SERIES

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50 Disassembly and assembly Disassembly and assembly

40.Flywheel 1) Install lock plate [1] and remove mounting bolt (1).

2) Remove rear oil seal (2).

2) Install eyebolt [2] to flywheel (2) and lift it off.

4 Flywheel: 60 kg

43.Piston and connecting rod assembly 1) Rotate the crankshaft and bring the piston to be removed to the bottom dead center.

2) Scrub the carbon off the top wall of the liner with fine sandpaper.

41.Flywheel housing assembly Remove 12 bolts (1) and remove flywheel housing (2).

4 Flywheel housing: 60 kg

a Before removing the piston and connecting rod assembly, measure the side clearance between the connecting rod and crankshaft with tool K. 3) Apply a marking to each of connecting rod caps (1) and connecting rods (2) on respective cylinders.

4) Remove bolt (3).

5) Tap connecting rod cap (1) with a plastic hammer, and remove connecting rod cap (1) and connecting rod bearing as a unit.

42.Rear cover 1) Remove rear cover (1).

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114E-5 SERIES

50 Disassembly and assembly Disassembly and assembly

a Store them carefully not to damage the mating faces of the connecting rod and connecting rod cap. If damaged, the connecting rod and connecting rod cap must be replaced.

6) From the oil pan side, push the piston and connecting rod assembly into the cylinder using a wooden bar ro similar object take it out from the cylinder head side while supporting piston (4). a Take care not to damage the inside of the cylinder with a corner of the connecting rod.

4] Using tool D, remove piston ring (7).

a Put the cylinder No. mark on the piston.

7) Remove the other piston and connecting rod assemblies according to the above procedure. a Take care not to damage the sliding portions of the pistons and bearings.

8) Disassemble the piston and connecting rod assembly according to the following procedure.

1] Remove snap ring (5).

a Store the piston, connecting rod, bearing, piston ring and piston pin in a set for each cylinder No. 44.Ne (crankshaft) speed sensor connector Disconnect Ne (crankshaft) speed sensor connector (1).

45.Crankshaft

2] Remove pin (6) to disconnect piston (4) and connecting rod (2).

3] Remove the snap ring on the opposite side.

114E-5 SERIES

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50 Disassembly and assembly Disassembly and assembly

a Before removing the crankshaft, measure its end play with tool L.

5) Lift off crankshaft (4).

1) Remove mounting bolt (2) of main cap (1).

2) Mark the position number on main cap (1). a Check that the embossed letters of "ABBTV", which situate in portion (A) on the side face of the main cap, are directed toward the rear of the cylinder block.

3) Insert bolt (2) into the bolt hole of main cap (1), and remove the main cap while shaking it.

4) Remove lower main bearing (3) from main cap (1). a Mark the position number of the removed bearing on its backside. (Do not use the bearing's sliding surface for the record.)

50-28

a When lifting up the crankshaft, take care not to hit it against the cylinder block. a Keep the crankshaft in a safe place so that its sliding portions does not be damaged.

4 Crankshaft: 85 kg

6) Remove speed sensor ring (5).

7) Remove one upper thrust bearing (6) at the center and six upper bearings (7). a Mark the installation position on the main caps, upper bearings, and upper thrust bearings (use the back side for the bearings), and store them in a set for each cap. And take care not to damage these parts.

114E-5 SERIES

50 Disassembly and assembly Disassembly and assembly

46.Tappet Remove 12 tappets (1).

1) Apply marking (A) to the cylinder liner installing position and install tool R on the top of the cylinder block. a Set arm [5] in such that it does not touch supporting sections [1], [2], [3] and [4] of cylinder liner (1). a Set tool R in such a way that it comes to the center of the top of the cylinder liner.

47.Piston cooling nozzle Remove bolts (1) and remove six piston cooling nozzles (2).

2) Rotate jack bolt [6] of tool R clockwise to pull up cylinder liner (1) from cylinder block (2), then remove cylinder liner (1) using both hands. a Mark the position No. on the removed cylinder liner.

48.Cylinder liner a Before removing the cylinder liner, measure its protrution using tool L.

49.Cylinder block 1) Sling and disconnect cylinder block (1) from repair stand (Tool A).

114E-5 SERIES

50-29

50 Disassembly and assembly Disassembly and assembly

4 Cylinder block: 245 kg 2) Remove tool B from cylinder block (1).

50-30

114E-5 SERIES

50 Disassembly and assembly Disassembly and assembly

General assembly of engine

(ENG114-A000-710-K-01-A)

a This document describes the general disassembly procedure for SAA6D114E-5.

Before starting your work, check the shapes, quantities, locations, etc. of the installed parts since they depend on the machine model. a When reusing a part, be sure to install it to its original position.

a When reusing the cylinder liner, install it to its original position and then set its installation direction by turning it by 45 deg. from the original position. (Move the pitted surface of the cylinder liner from the position where it has been pitted.)

1. Cylinder block 1) Install tool B to the cylinder block.

2) Sling cylinder block (1) and install it to repair stand (Tool A).

4 Cylinder block: 245 kg

1) Apply engine oil to the O-ring sealing portion of cylinder liner (1). a Apply a little amount of oil just before inserting the cylinder liner.

2 O-ring sealing portion: Engine oil (EO15W-40) 2) Install O-ring (3) to cylinder liner (1).

2. Cylinder liner a Before inserting the cylinder liner, clean it to remove all deposits and broken pieces from sealing faces (A), (B) and (C) and polish those faces until the machined surfaces appear. (At this time, take care not to scrub excessively.)

a When fitting the O-ring, check that it is not twisted.

a Apply clean engine oil to surfaces (A) and (B).

2 Sealing surfaces (A) and (B): Engine oil (EO15W-40)

3) Push cylinder liner (1) into cylinder block (2) using both hands. a If the cylinder liner does not enter the cylinder block smoothly, check the cylinder block for burrs and sharp fins since O-ring can be damaged by them.

4) Using tool S, press fit cylinder liner (1).

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a When reusing a the tappet, be sure to combine it with the same camshaft as before. a Do not install a used tappet to a new camshaft.

1) Apply engine oil to the tappet.

2 Tappet: Engine oil (EO15W-40)

5) Using tool Y and cylinder head mounting bolt (4), install cylinder liner (1).

3 Mounting bolt: 68 ± 10 Nm {6.93 ± 1.02 kgm}

2) Install 12 tappets (1).

6) After press fitting the cylinder liner, measure the projection of the cylinder liner with tool L. a Measure the projection at four places equally spaced on the periphery. a Protrusion of cylinder liner: 0.026 to 0.122 mm

a Do not turn the cylinder block more than 90 deg. Otherwise, tappets come off from the mounting holes.

4. Piston cooling nozzle Install six piston cooling nozzles (2) and secure them with bolt (1).

3 Mounting bolt: 27 ± 3 Nm {2.75 ± 0.31 kgm}

7) If the protrusion of the cylinder liner changes 0.025 mm or greater within 180 deg. of the liner periphery, repeat Steps 5) and 6) to set it in the specified dimension.

3. Tappet

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5. Crankshaft 1) Install six upper bearings (7) and one upper thrust bearing (6).

4 Crankshaft: 85 kg

a Install them by aligning the protruding portion of each bearing to the notch of the cylinder block. a Check that no dirt or dust is sticking to the back side of the bearing before assembling. a Apply engine oil to the inside of the bearing. In this case, do not apply engine oil to the back side of the bearing. a When reusing bearings, check the marks that are put on them when they are removed, and install them in their original positions.

2 Inside of bearing: Engine oil (EO15W-40)

2) Install speed sensor ring (5).

1] Use new bolts (Do not reuse the removed bolts).

2] Tighten the bolts on the right side and left side alternately.

3 Mounting bolt: 8 Âą 2 Nm {0.82 Âą 0.2 kgm}

4) Install lower bearing (3) aligning its protruding portion to the notch of main cap (1). a Check the position number on the back side of the bearing.

5) Apply engine oil to the journal surfaces of the crankshaft.

2 Crankshaft journal surface: Engine oil (EO15W-40) 6) When installing main cap (1), check the mounting position mark on it and then direct the embossed letters of "ABBTV" in portion "A" toward the rear side of the cylinder block. a Push in by hitting it lightly with a plastic hammer or rubber hammer.

7) Tighten main cap mounting bolts (2) in the sequence shown in the figure ([1] to [14]). a Apply engine oil to the bolts.

2 Mounting bolt: Engine oil (EO15W-40)

3) Sling and install crankshaft (4). a Install it carefully so as not to damage its bearings.

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8) After tightening the bolts, turn the crankshaft (4) to make sure it rotates smoothly.

9) Measure the end play of the crankshaft (4) using tool L. a End play: 0.109 to 0.360 mm

3 Main cap mounting bolt: 1] 60 ± 5 Nm {6.1 ± 0.51 kgm} 2] 115 ± 5 deg. (by using angle tightening tool J).

6. Piston and connecting rod assembly 1) Using tool D, install piston rings (7) to the piston.

• When not using tool J Put paint marks on the main cap and bolts, and retighten the bolts by 115 ± 5 deg.

2) Fitting oil ring a Fit oil ring (9) so that its abutment joint is at 180 deg. from the end of expander (8).

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3) Fit second ring (10) with the "TOP" stamping mark, which is near the abutment joint, directed upward.

4) Fit top ring (11) with the "dot" mark, which is near the abutment joint, directed upward.

5) When fitting each ring, set the abutment joint off the thrust, anti-thrust, and piston axis directions.

1] Apply engine oil to the piston pin hole and piston pin.

2 Piston pin hole and piston pin: Engine oil (EO15W-40)

2] Insert piston pin (6) and assemble piston (4) to connecting rod (2).

3] Install snap rings (5) to both sides. a Apply engine oil to the piston rings and piston skirt.

2 Piston ring and piston skirt: Engine oil (EO15W-40) 6) Assembling of piston and connecting rod a Make sure that when the "FRONT" mark in section (A) of piston (4) is set facing upward, the match mark of the connecting rod cap comes to section (B) of connecting rod (2).

7) Install bearing (12) to connecting rod (2) and connecting rod cap (1). a Check that the back side of the bearing is free from foreign matter. a Install the bearing by aligning the protruding portion of the bearing to the notches of the connecting rod and connecting rod cap.

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8) Set the crankshaft to the bottom dead center position for the cylinder to be installed, and apply engine oil to the inside of the cylinder.

2 Inside of cylinder: Engine oil (EO15W-40) 9) Set the "FRONT" mark of piston (4) in the front side of the cylinder block and insert the piston and connecting rod assembly. a Check the directions of the end gap of the piston rings again. a When inserting the connecting rod, take care not to damage the wall of the cylinder. a When inserting the connecting rod, take care not to hit the cooling nozzle with it.

3 Mounting bolt (Tighten both bolts alternately) • HB335–1,HB335LC-1 HB365–1,HB365LC-1 1] 30 ± 5 Nm {3.06 ± 0.51 kgm} 2] 50 ± 5 Nm {5.1 ± 0.51 kgm} 3] 60 ± 5 deg. (Use angle tightening tool J) • Machine model other than models previously mentioned 1] 30 ± 5 Nm {3.06 ± 0.51 kgm} 2] 70 ± 5 Nm {7.14 ± 0.51 kgm} 3] 60 ± 5 deg. (Use angle tightening tool J)

a Using tool E, compress the piston rings and push in the piston head with a wood bar, etc.

10)Tighten connecting rod cap (2) using bolt (1) according to the following procedure.

• When not using tool J Put paint marks on the connecting rod cap and bolts, and retighten the bolts by 60 ± 5 deg.

a Apply engine oil to the threaded portion of the bolt and inside of the connecting rod bearing.

2 Inside of connecting rod bearing: Engine oil (EO15W-40)

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3 Mounting bolt: 40 Âą 2.0 Nm {4.08 Âą 0.20 kgm}

11)After installing the piston and connecting rod assembly, turn the crankshaft to check that it rotates smoothly.

12)Measure the end play between the connecting rod and crankshaft using tool K. a Side clearance: 0.130 to 0.275 mm

8. Camshaft a Rotate the crankshaft to set the No. 1 cylinder to the top dead center.

1) Apply engine oil to the camshaft bore, camshaft journal and lobe, then install camshaft gear assembly (1) while lightly pushing and rotating it. a When installing the camshaft, take care not to damage the cam bushing.

2 Sliding surface of camshaft: Engine oil (EO15W-40)

7. Front gear housing 1) Install guide bolts [1], then install gasket (1).

2) Align the timing mark of camshaft gear assembly (1) to that of crankshaft gear (2).

a Protrusion of gasket from oil pan mounting surface: Max. 0.25 mm 2) Install gear housing (2). a After tightening the gear housing temporarily, remove the guide bolt. a Tighten the mounting bolts in the numerical order shown in the figure ([1] to [5]).

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3) Install thrust plate (4) using bolt (3).

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3 Mounting bolt: 24 ± 4 Nm {2.45 ± 0.41 kgm}

4) Measure the end play of camshaft gear assembly (1) using tool L. a The end play depends on the thickness of the thrust plate and the groove of the camshaft.

2 Space in pump rotor and idler shaft bore: Engine oil (EO15W-40)

2) Tighten oil pump assembly (2) temporarily using bolt (1).

a End play: 0.10 to 0.36 mm

a Insert oil pump idler shaft (3) into the positioning hole of the cylinder block securely.

5) Measure the backlash of camshaft gear assembly (1) using tool L. a Backlash: 0.075 to 0.325 mm

3) Tighten oil pump mounting bolts (1) in the sequence shown in the figure ([1] to [4]).

9. Oil pump 1) Fill the space in the pump rotor and idler shaft bore with engine oil and rotate the rotor by two turns.

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3 Mounting bolt: 1st time: 15 ± 1 Nm {1.53 ± 0.1 kgm} 2nd time: 24 ± 4 Nm {2.45 ± 0.41 kgm}

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4) Rotate the crankshaft by one turn and measure backlash (C) between the oil pump and idler gear using L. a Backlash: 0.205 ± 0.125 mm

12.Supply pump 1) Before installing the supply pump, check that dowel pin (1) of the supply pump drive shaft is not damaged. a If the dowel pin is damaged, replace the supply pump and supply pump gear.

10.Water pump Install water pump (1).

3 Mounting bolt: 24 ± 4 Nm {2.45 ± 0.41 kgm}

2) Install a new O-ring (2) to the supply pump flange.

2 O-ring (2):

11.Supply pump gear When installing supply pump gear (2), align its timing mark "00" to timing mark "0" of camshaft gear assembly (1).

Engine oil (EO15W-40) 3) Install a new O-ring (3) to the supply pump lubrication port.

4) Using contact cleaner, clean the contact surface between the periphery of supply pump drive shaft and the inner diameter side of the supply pump gear.

5) Before installing the supply pump, check that the contact surface between the periphery of the supply pump drive shaft and the inner diameter side of the supply pump gear is dry and free from foreign matter.

a Rotate the crankshaft in the normal direction to set stamped line of the supply pump gear to the top, and set the No. 1 and No. 6 cylinders to the compression top dead center (TDC).

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6) Align dowel pin (1) of supply pump drive shaft (5) to key slot (b) of supply pump gear (4) and push it into the slot.

7) Install washer (6) to supply pump drive shaft (5), and tighteen nut (7) loosely.

10)Tighten nut (7).

3 Mounting nut: 180 ± 13 Nm {18.4 ± 1.33 kgm}

13.Front oil seal 1) Set tool T on front oil seal (8) from pilot [1] side. a Pilot [1] is a plastic part provided inside the front oil seal. Since it functions as the guide tool when installing the crankshaft, you must not remove it from the front oil seal.

8) Tighten nut (9) until its looseness is eliminated, then fix supply pump (8).

2 Mounting nut (9): Adhesive (LT-2) a Mounting bolts on the cylinder head side and supply pump flange side must be tightened after the cylinder head is installed.

9) Tighten supply pump mounting nut (9).

3 Mounting nut (9): 43 ± 6 Nm {4.38 ± 0.61 kgm}

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2) Install front oil seal (8) from inside of front oil seal carrier (7). a The installed height of the front oil seal must be the same as that of the inner flat surface of the front oil seal carrier.

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3) Apply pilot [1] to the crankshaft and push it by hand into the crankshaft together with front oil seal carrier (7).

4) Remove pilot [1].

14.Engine front cover a Check that the end corner and lip sliding surface of the crankshaft are free from flaw, burr, sharp fin, rust, etc.

5) Apply liquid gasket to the following portions and install front oil seal carrier (7).

a Do not apply oil or grease to the crankshaft and seal lip. Thoroughly wipe off oil and grease from the crankshaft.

1) Install cover (5) using mounting bolt (6).

• All circumferences (a) of inside of front oil seal carrier (7) • Threaded portion (b) of bolt (9) and contact surface (c) of front oil seal carrier • Threaded portion (d) of nut (10)

2 Cover mating face: Liquid gasket (LG-7)

2 Portions (a), (b), (c) and (d) indicated in the figure: Liquid gasket (LG-7)

2) Tighten the mounting bolts in the numerical order shown in the figure ([1] to [26]).

3 Mounting bolt: 6) Tighten mounting nut (10) of front oil seal carrier (7) in the sequence shown in the figure ([1] to [5]).

3 Mounting nut: 8 ± 1 Nm {0.82 ± 0.1 kgm}

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Position of bolt

Size of bolt

1, 5, 8, 10, 16, 17, 19, 20, 22, and 23

M8 x 1.25 – 25

2

M8 x 1.25 – 35 (Stud bolt)

4, 7, and 13

M8 x 1.25 – 25 (Stud bolt)

3, 6, 9, 11, 12, 14, 15, 18, 21, 24, 25, and 26

M8 x 1.25 – 25

Tightening torque 30 ± 2 Nm {3.06 ± 0.2 kgm} 30 ± 2 Nm {3.06 ± 0.2 kgm} 30 ± 2 Nm {3.06 ± 0.2 kgm} 40 ± 2 Nm {4.08 ± 0.2 kgm}

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3) Remove pilot tool [1] from the front seal.

4) Install dust seal (9). a Push in the dust seal until it reaches the oil seal.

15.Rear oil seal 1) Apply neutral detergent to the periphery of the rear oil seal. a Portion (P) is a plastic part provided inside the rear oil seal. Since it functions as the pilot (guide tool) when installing the crankshaft, you must not remove it from the rear oil seal.

2) Install rear oil seal (2) to rear cover (1).

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3) Using alignment tool (positioning tool) (A) attached to the rear oil seal, push rear oil seal (2) into rear cover (1) up to a proper depth.

4) Remove alignment tool (A).

16.Rear cover 1) Clean, degrease, and dry the gasket faces against the rear cover and cylinder block.

2) Clean, degrease, and dry the seal lip sliding surface (peripheral surface of the crankshaft).

a Check that the end corner and lip sliding surface of the crankshaft are free from flaws, burrs, sharp fins, rusts, etc.

3) After install guide pin [1] and gasket (3), apply pilot (P) to crankshaft (4) and push it by hand into crankshaft (4) together with rear cover (1).

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2 Housing mounting face: Liquid gasket (LG-7) 4) Remove the pilot (P).

9) Measure facial runout and radial runout of the rear oil seal to the crankshaft. a Facial runout: Max. 0.38 mm 5) Adjust rear cover (1) and both sides (B) of oil pan rail to the same height.

• Horizontal direction: Max.0.00 ± 0.10 mm • Vertical direction: Max. 0.150 mm

a Radial runout: Max. 0.25 mm 10)Install seal (5) to seal cover (1).

11)Cut off the protrusion of gasket (3). (on both sides) 6) Install alignment tool (A) again, and check that rear oil seal (2) is inserted to a proper depth. a Leave alignment tool (A) installed without trying to remove it.

7) Remove the guide pin and tighten mounting bolts in the sequence shown in the figure ([1] to [8]).

a Protrusion from bottom of cylinder block: Max.0.25 mm a Take care so that the cut gasket does not drop in the engine.

3 Mounting bolt: 13 ± 2 Nm {1.33 ± 0.2 kgm} 8) Remove alignment tool (A).

17.Oil pan 1) Apply liquid gasket to the clearance e range between the cylinder block and gear housing, and between the cylinder block and rear cover.

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2 Clearance e range: Liquid gasket (LG-7)

2) Install guide pin [1] to cylinder block (1), and install gasket (2) to them.

6) Apply liquid gasket to the entire circumference of oil pan (6) at the gasket side mating face.

2 Oil pan: 3) Install bed plate (3).

4) Insert the gasket to the end flange and install suction tube (4).

Liquid gasket (LG-7)

2 Flange: Liquid gasket (LG-7) 3 Flange mounting bolt: 10 ± 2 Nm {1.02 ± 0.2 kgm}

7) Install oil pan (6) using mounting bolts (7).

8) Tighten oil pan mounting bolts (7) in the numerical order shown in the figure ([1] to [32]).

3 Mounting bolt: 24 ± 4 Nm {2.45 ± 0.41 kgm} 5) Apply liquid gasket to the hatched portion of the bed plate side mating face and install gasket (5).

2 Gasket (Mating face of bed plate): Liquid gasket (LG-7)

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3 Mounting bolt: 77 ± 12 Nm {7.85 ± 1.22 kgm}

4) After installing the flywheel housing, measure the radial runout and facial runout with tool L. a Radial runout: Max. 0.20 mm

18.Flywheel housing assembly 1) Apply a continuous bead of liquid gasket 1 to 3 mm in diameter to the mounting flanged surface of the flywheel housing and around the mounting bolt holes.

2 Mounting flanged surface and around mounting bolt holes: Liquid gasket (LG-7) 2) Install flywheel housing (1) using mounting bolts.

a Facial runout: Max. 0.20 mm • Measurement of radial runout 1) Install tool L to the crankshaft end.

2) Set the probe of the dial gauge perpendicular to the spigot joint portion of the flywheel housing.

3) Set the dial gauge reading to “zero”, rotate the crankshaft by one turn, and measure the difference between the indicated lowest and highest values. a After the crankshaft is rotated by one turn, check that the dial gauge indicates the value at the start of rotation.

4 Flywheel housing: 60 kg

• Measuring facial runout 1) Similarly to measurement of the radial runout, set the probe of the dial gauge perpendicular to the end face of the flywheel housing.

3) Tighten flywheel housing mounting bolts (2) in the numerical order shown in the figure ([1] to [12]).

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a When measuring, bring the crankshaft to the front or rear side so that an error does not be caused by the end play.

2) Set the dial gauge reading to “zero”, rotate the crankshaft by one turn, and measure the difference between the indicated lowest and highest values.

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19.Flywheel 1) Install guide bolt [2] and flywheel (1). a Apply a continuous bead of liquid gasket 1 to 3 mm in diameter around the bolt holes on the crankshaft mounting surface (eight places).

2 Flywheel mounting surface: Liquid gasket (LG-7) 4 Flywheel: 60 kg

3) After installing the flywheel, measure the radial runout and face runout with tool L. a Radial runout: Max. 0.13 mm a Facial runout: Max. 0.20 mm • Measurement of radial runout 1) Set tool L to the flywheel housing.

2) Bring the dial gauge probe into contact with faucet joint portion (a) or the outer perimeter surface of the flywheel at a right angle.

3) Give the flywheel one turn and measure the largest difference among the values indicated by the dial gauge. a Give the flywheel one turn and check that the dial gauge indicates the same value as the one at the start of rotation.

• Measuring facial runout 1) As in the case of measurement of radial runout, bring the dial gauge probe into contact with end surface (b) near the outer perimeter of the flywheel at a right angle.

2) Procedure for tightening bolts 1] Install lock plate [1].

2] Tighten the mounting bolts in the numerical order shown in the figure ([1] to [8]).

a When measuring, bring the crankshaft to the front or rear side so that an error does not be caused by the end play.

2) Give the flywheel one turn and measure the largest difference among the values indicated by the dial gauge.

3 Mounting bolt: 137 ± 7 Nm {14.0 ± 0.71 kgm}

20.Cylinder head assembly 1) Assemble the cylinder head according to the following procedure:

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1] Install valve seals (7-1) and (7-2). • Exhaust Valve: (7-1) • Intake Valve: (7-2)

2] Apply engine oil to the valve stem and the inside of valve guide, and install valve (6).

2 Valve stem and inside of valve guide: Engine oil (EO15W-40)

a Hit the valve stem lightly with a plastic hammer to check that the valve 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 within the allowable limit length of the bolt.

2] Allowable limit length of bolt: Max. 162.6 mm a If a bolt is out of the allowable limit, do not reuse it but replace it.

3] Turn the topside of cylinder head upward, and then install valve spring (3) and upper seat (5).

3) Check that there is no dirt or foreign objects on the cylinder head mounting surface and inside the cylinder, then install cylinder head gasket (8) to cylinder block (1). a Check that the holes of the gasket is fitted to the those of the cylinder block.

4] Using tool C, compress valve spring (3) to install valve collet (4).

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4) Install cylinder head assembly (2) to cylinder block (1).

4 Cylinder head assembly: 95 kg

5) Tighten bracket (12) of supply pump (9) to cylinder head (2) according to the following procedure.

a First, tighten the mounting bolts by two or three turns with the fingers, and then tighten them according to the following procedure.

2 Threaded portion and seat of bolt: Engine oil (EO15W-40) 3 Cylinder head mounting bolt: 1] 50 ± 7 Nm {5.1 ± 0.71 kgm}

1] Tighten bracket (12) temporarily using bolts (10) and (11).

2] Tighten cylinder head side mounting bolt (10).

3 Mounting bolt (10): 43 ± 6 Nm {4.38 ± 0.61 kgm} 3] Tighten mounting bolt (11) of supply pump flange side.

3 Mounting bolt (11): 77 ± 12 Nm {7.85 ± 1.22 kgm}

2] 150 ± 10 Nm {15.3 ± 1.02 kgm} 3] Loosen every bolt by 360 deg.

4] 115 ± 5 Nm {11.7 ± 0.51 kgm} 5] Check that the bolt is tightened to 115 ± 5 Nm {11.7 ± 0.51 kgm}.

6] 120 ± 5 deg. (Using angle tightening tool J)

21.Intake manifold cover 1) Install gasket (3) to cylinder head (4).

2 Both sides of gasket: Liquid gasket (LG-7)

• When not using angle tightening tool J Put paint marks on the cylinder head and bolts, and retighten the bolts by 120 ± 5 deg.

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2) Install intake manifold cover (1) and bracket (2).

3 Mounting bolt: 24 Âą 4 Nm {2.45 Âą 0.41 kgm} a Note that some bolts are to be tightened when installing the high-pressure pipe.

(Not every bolt is tightened at this point.)

22.Injector assembly a Check that the injector sleeve is free of scratches and dirt. a When replacing the injector with a new one, replace the inlet connector with a new one, too.

1) Check inlet connector (11) along the following items. If any problems are found, replace it.

1] Burrs or wear are recognizable in front end (a) and rear end (b) of the inlet connector.

2] There is foreign matter in the edge filter at rear end (c) of the inlet connector.

3] The O-ring at upper portion (d) of the inlet connector is cracked or deteriorated.

4] There is a worn part or an uneven seat contact mark on seating face (e) in the front end of the inlet connector. a If high-pressure fuel leaks through the inlet connector, the seating surface erodes and fine streaks or cracks appears. If the above phenomenon is observed, replace the inlet connector and injector.

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2) Install gasket (12) and O-ring (13) to injector (7).

3) Apply engine oil to the O-ring and head side of injector (7).

2 O-ring and head side of injector: Engine oil (EO15W-40)

4) Insert injector (7) into the cylinder head, directing its fuel inlet hole toward the intake manifold.

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8) Tighten mounting bolts (5) of holder (6) alternately.

3 Bolt: 10 ± 2 Nm {1.02 ± 0.2 kgm} a The top of the holder must be in parallel with the top of the cylinder head.

• Allowable angle: 2.4 deg.

9) Tighten inlet connector (11) permanently using the retaining nut.

5) Install holder (6) and screw mounting bolts (5) three to four turns by fingers.

3 Retaining nut (10) (permanent tightening): 50 ± 4 Nm {5.1 ± 0.41 kgm} a Apply liquid gasket to (f) (hatched area) of the cylinder head and retaining nut (10).

2 Cylinder head and retaining nut (10) (f) (hatched area): Liquid gasket (LG-7)

6) Apply engine oil to the O-ring and head side mounting hole of inlet connector (11).

2 O-ring and head side of inlet connector: Engine oil (EO15W-40) 7) Secure inlet connector (11) by tightening retaining nut (10) lightly. a Then, tighten the retaining nut permanently. Be sure to tighten to the specified torque each time. If the tightening torque is insufficient or too high, fuel may leak into the engine.

3 Retaining nut: 15 ± 5.0 Nm {1.53 ± 0.51 kgm}

23.Push rod 1) Apply engine oil to the push rod socket.

2 Push rod socket: Engine oil (EO15W-40) 2) Install push rod (1). a Check that the push rod is in the tappet.

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Adjust the valve clearance according to the following procedure. a Adjust the valve clearance so that the clearance between the crosshead and rocker arm comes to the following value. a Valve clearance (when the engine is cold) Intake valve 0.30 ± 0.08 24.Rocker arm and crosshead 1) Install crosshead (3).

2) Install rocker arm assembly (2) and tighten bolt (1).

Unit: mm Exhaust valve 0.56 ± 0.08

1) Rotate the crankshaft in the normal direction to set stamped line (a) of supply pump drive gear (1) to the top, and set the No. 1 cylinder to the compression top dead center (TDC).

a Check that the spherical portion of adjustment screw (5) is fitted properly in the socket of push rod (4), and tighten the mounting bolt.

3 Mounting bolt: 65 ± 5 Nm {6.63 ± 0.51 kgm}

2) When the No. 1 cylinder is at the compression top dead center, adjust the valve clearance indicated by q of the valve arrangement drawing.

a When reusing the crosshead, install the same intake and exhaust valves in the same direction because the shapes of its holes (a) and (b) are different, • A new crosshead may be installed in either direction.

3) Insert feeler gauge K between rocker arm (2) and crosshead (3), and fix adjustment screw (4) lightly so that you can move it.

4) Tighten lock nut (5) in this position.

3 Lock nut: 24 ± 2.4 Nm {2.45 ± 0.24 kgm} a After tightening the lock nut, check the valve clearance again.

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3 Mounting bolt: 9 ± 2 Nm {0.92 ± 0.2 kgm}

5) After adjusting all of the valves marked with q, rotate the crankshaft in the normal direction by one turn to face stamped line (a) of supply pump gear (1) to the bottom, and set the No. 6 cylinder to the compression top dead center.

27.Common rail pressure sensor and pressure limiter 1) To replace common rail pressure sensor (2), follow the procedures below. a Do not remove common rail pressure sensor (2) from common rail (1) unless replacement of the sensor is necessary. a Once the common rail pressure sensor is removed from the common rail, be sure to replace it with a new one.

6) While the No. 6 cylinder is at the compression top dead center, adjust the valve clearances marked with Q in the valve arrangement drawing. a The adjustment procedure is as same as Steps 3) and 4).

7) After completing adjustment of every valve clearance, install cap (6).

1] Before removing the common rail pressure sensor, throughly remove any mud or other foreign objects from the area around it and clean it.

2] Remove the common rail pressure sensor.

3] Check the common rail pressure sensor connector for crack, breakage, damage of the seal, foreign matter on the pin and corrosion, bend and breakage of the pin.

4] Install a new common rail pressure sensor.

2 Threaded portion of common rail pressure sensor: Gear oil (#90) 3 Common rail pressure sensor: 70 ± 5 Nm {7.14 ± 0.51 kgm} 2 Threaded portion of adapter: Gear oil (#90) 3 Adapter: 37 ± 4 Nm {3.77 ± 0.41 kgm}

26.Ne (crankshaft) speed sensor connector Install Ne (crankshaft) speed sensor connector (1).

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28.Common rail, high-pressure pipe and connector block k Do

not use high-pressure pipes with bending modification.

k Be

sure to use the genuine high-pressure pipe fixing clamp and observe the tightening torque.

k Install

2) To replace pressure limiter (3), follow the procedures below.

1] Before removing the pressure limiter, thoroughly remove mud or other foreign objects from area around it and clean it.

2] Remove the pressure limiter.

3] If the leakage from the pressure limiter exceeds the specified value, do not reuse it.

4] Check that there is no damage on highpressure fuel sealing surfaces (a) on the pressure limiter and common rail.

5] Install a new pressure limiter.

each high-pressure pipe and wiring harness at least 10 mm apart from each other.

a When installing each high-pressure pipe, check the taper seal of its joint (portion (a): part of 2 mm from the end) for visible lengthwise slit (b) and spot (c), and check portion (d) (end of taper seal: part at 2 mm from the end) for stepped-type wear caused by fatigue that is able to be felt with your finger nail. If any of those defects exist, they may cause fuel leakage. In this case, replace the high-pressure pipe.

2 Threaded portion of pressure limiter: Gear oil (#90) 3 Pressure limiter: 100 ± 4 Nm {10.2 ± 0.41 kgm} a Excessive tightening can cause leakage. Take care not to tighten too strongly.

6] Check that adapter (4) is not damaged. a If adapter (4) is removed, use new copper washer (5) and apply new gear oil (#90) to the adapter and tighten it.

1) Install common rail (16) and tighten it temporarily using mounting bolts (17) and (18). (Manual tightening)

3 Adapter: 37 ± 4 Nm {3.77 ± 0.41 kgm}

2) Install high-pressure pipe (7) between the supply pump and common rail.

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a Install the high-pressure pipe together with sandwich clamp (9) and tighten the bracket lightly.

3 Mounting nut: 24 ± 4 Nm {2.45 ± 0.41 kgm}

3 Sleeve nut: 37 ± 4 Nm {3.77 ± 0.41 kgm} 3) Install high-pressure pipes (1) to (6) between the common rail and injector. a Install the high-pressure pipe together with sandwich clamp (9) and tighten the bracket lightly.

3 Sleeve nut: 37 ± 4 Nm {3.77 ± 0.41 kgm} 4) Tighten the mounting bolt for common rail (16) to the specified torque.

3 Mounting bolt: 43 ± 4.0 Nm {4.38 ± 0.41 kgm} 5) Loosen every sandwich clamp (9) for the high-pressure pipes.

6) Tighten the bracket of sandwich clamp (9) that fixes the high-pressure pipe.

3 Mounting bolt: 24 ± 4 Nm {2.45 ± 0.41 kgm} a Tighten the sandwich clamp of highpressure pipe (3) after installing the intake manifold.

7) Tighten sandwich clamp (9).

3 Mounting bolt: 6 Nm {0.61 kgm} 8) Install 14 fuel spray prevention caps (8).

11)Install tube (12). (center side of supply pump and centralized block) 3 Joint bolt: 24 ± 4 Nm {2.45 ± 0.41 kgm} 3 Tube clamp mounting bolt (15): 43 ± 6 Nm {4.38 ± 0.61 kgm} 12)Install tube (13). (left side of common rail pressure limiter and centralized block) 3 Joint bolt: 24 ± 4 Nm {2.45 ± 0.41 kgm} 13)Install tube (14). (right side of cylinder head and centralized block) 3 Joint bolt: 24 ± 4 Nm {2.45 ± 0.41 kgm}

a Set the slits of each bellows out and down. a The fuel spray prevention caps are installed so that fuel does not spout over the hot parts of the engine and catch fire when it leaks for some reason.

29.Rocker housing and head cover 1) Install the gasket to rocker housing (1).

2) Install rocker housing (1) to cylinder head (2).

3) Tighten mounting bolts in the sequence shown in the figure ([1] to [7]).

3 Mounting bolt: 9) Install connector block (10).

3 Mounting bolt: 24 ± 4 Nm {2.45 ± 0.41 kgm} 10)Install wiring harness connector bracket (11).

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24 ± 4 Nm {2.4 ± 0.4 kgm} 4) When you have removed injector connectors (7), install them to rocker housing (1).

3 Injector wiring harness connector: 10 ± 2 Nm {1.02 ± 0.2 kgm} 114E-5 SERIES

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5) Install wiring harness (4) to injector (3).

3 Mounting nut: 1.25 ± 0.25 Nm {0.13 ± 0.03 kgm} a Locations of wiring harnesses a b c d

Color of cable Yellow Orange Red Brown

Cylinder No. Right side 1, 3, 5 Left side Right side 2, 4, 6 Left side

a Install injector wiring harness terminals (5) in a direction that does not interfere with the movement of rocker arm (6).

a Take care when installing wiring harness (4) to prevent it from bumping against the inner wall of rocker housing (1), disengaging from guide (8) or being bent forcibly. a Be sure to maintain a minimum clearance of 3 mm (E) between wiring harness (4) and rocker housing (1). a Be sure to maintain a minimum clearance of 3 mm (F) between wiring harness (4) and rocker arm (6).

6) Install the gasket to head cover (9), and install head cover (9) to rocker housing (1).

3 Head cover mounting bolt: 12 ± 2 Nm {1.22 ± 0.2 kgm}

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7) Install lifting plate (10) to cylinder head (2).

3 Mounting bolt: 77 ± 12 Nm {7.85 ± 1.22 kgm}

2) Install coolant outlet connector (2). a The shape depends on the applicable machine model.

3 Mounting bolt: 24 ± 4 Nm {2.45 ± 0.41 kgm}

30.Boost pump 1) Install the gasket and install boost pump (4) using two mounting bolts (3).

3 Mounting bolt: 77 ± 12 Nm {7.85 ± 1.22 kgm} 2) Install hose (1) to cylinder block (2).

3 Sleeve nut: 25 ± 1.5 Nm {2.55 ± 0.15 kgm}

32.Coolant inlet connector 1) Install coolant inlet connector (1).

3 Mounting bolt: 24 ± 4 Nm {2.45 ± 0.41 kgm} 2) Install plug (2).

3 Plug: 85 ± 8 Nm {8.67 ± 0.82 kgm}

31.Thermostat and coolant outlet connector 1) Fit gasket and install thermostat (1).

33.EGR cooler and exhaust manifold 1) Install plugs (4) and (5).

3 Plug (4): 115 ± 12 Nm {11.7 ± 1.22 kgm}

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3 Plug (5): 36 ± 5 Nm {3.67 ± 0.51 kgm} 2) Install EGR mount bracket (3).

3 Mounting bolt: 43 ± 6 Nm {4.38 ± 0.61 kgm}

4) Install EGR cooler (2) to exhaust manifold (1) and EGR mount bracket (3), then tighten the bracket by your fingers.

5) Tighten mounting bolt (7) for EGR cooler (2) and exhaust manifold (1).

3 Mounting bolt: 43 ± 6 Nm {4.38 ± 0.61 kgm} 6) Tighten mounting bolts (8) for EGR cooler (2) and EGR mount bracket (3).

7) Install tube (9) to EGR cooler (2).

3 Mounting bolt: 9.5 ± 2 Nm {0.97 ± 0.2 kgm} 3 Hose clamp: 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}

3) Install a new gasket and install exhaust manifold (1).

34.Starting motor assembly 1) Apply a continuous bead of liquid gasket (A) 4 mm in diameter on the gasket.

3 Mounting bolt (6) tightening procedure: 1] Tighten bolts in the in the numerical order of [1] to [12] shown in the figure to a torque of 53 ± 5 Nm {5.4 ± 0.51 kgm}.

2] Only as for bolts [1] to [4] shown in the figure, retighten them to a torque of 53 ± 5 Nm {5.4 ± 0.51 kgm} in the numerical order.

2 Both sides of gasket: Liquid gasket (LG-7)

2) Install the gasket, then install starting motor assembly (1) using bolt (2) and nut (3).

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4 KVGT: 30 kg

35.KVGT 1) Install tube (4).

4) Tighten mounting nut (5) and hose clamp (6) for KVGT (1). a Install one of mounting nuts (5a) to the bottom.

3 KVGT mounting nut: 55 ± 6 Nm {5.61 ± 0.61 kgm} 3 Hose clamp: 5 ± 1 Nm {0.51 ± 0.1 kgm}

2) Install new gasket (2) to exhaust manifold (3).

5) Install bracket (7).

3) Install KVGT (1) by slinging and install it by inserting tube (4) to the hose.

a Since two mounting bolts are used for the sensor bracket, too, tighten them after the sensor bracket is installed.

3 Mounting bolt: 43 ± 6 Nm {4.38 ± 0.61 kgm} 6) Install tube (8) and tighten bracket (7) lightly.

7) Install the gasket and install tube (8) to EGR cooler (9).

3 Mounting bolt: 24 ± 4 Nm {2.45 ± 0.41 kgm} 8) Install tube (8) and tighten bracket (7) firmly.

3 Mounting bolt: 43 ± 6 Nm {4.38 ± 0.61 kgm}

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9) When connector block (11) is disconnected from bracket (10) during disassembly, install connector block (11) and bracket (10).

3 Mounting bolt: 24 ± 4 Nm {2.45 ± 0.41 kgm} 10)Install bracket (10), which is installed with connector block (11) and hoses (12), (13) and (14), to exhaust manifold (3).

3 Mounting bolt: 43 ± 6 Nm {4.38 ± 0.61 kgm} 11)Install hoses (12) and (13) to the EGR cooler (9).

13)Install sensor bracket (15) to bracket (7).

3 Mounting bolt: 43 ± 6 Nm {4.3 ± 0.6 kgm} 14)Install tube (16).

3 Sleeve nut (sensor bracket side): 24.5 ± 9.5 Nm {2.5 ± 0.97 kgm} 3 Sleeve nut (exhaust manifold side): 18 ± 3 Nm {1.84 ± 0.31 kgm}

3 Sleeve nut: 15 ± 1 Nm {1.53 ± 0.1 kgm}

36.Oil cooler, oil filter and tubes 1) Install cooler gasket (5) and oil cooler (4).

2) Install cover gasket (3) and oil cooler cover (2) using bolts (6).

12)Install the gasket and install hose (14) to KVGT (1).

3 Joint bolt: 40 ± 4 Nm {4.08 ± 0.41 kgm} a When hose (14) is disconnected from connector block (11) 3 Sleeve nut: 36 ± 4 Nm {3.67 ± 0.41 kgm}

3) Tighten the bolts in the numerical order shown in the figure [1] to [11].

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3 Mounting bolt: 1] 15 ± 4 Nm {1.53 ± 0.41 kgm} 2] 27 ± 4 Nm {2.75 ± 0.41 kgm}

7) Install tube (17) to plug (16), which is installed to KVGT (15) and the cylinder block.

3 Joint bolt (KVGT side): 40 ± 5 Nm {4.08 ± 0.51 kgm} 3 Sleeve nut (cylinder block side): 35 ± 5 Nm {3.57 ± 0.51 kgm}

4) Install tube (9) to plug (7) and EGR cooler (8).

3 Hose clamp (10): 5 ± 1 Nm {0.51 ± 0.1 kgm} 3 Mounting nut (oil pump bracket) (11): 10 ± 2 Nm {1.02 ± 0.2 kgm} 3 Mounting bolt (bracket on EGR cooler side) (12): 24 ± 4 Nm {2.45 ± 0.41 kgm}

5) Install hose (13) to tube (9).

6) Install tube (14) to oil cooler cover (2).

8) Apply engine oil (EO15W-40) to the oil filter seal.

9) Supply clean engine oil (EO15W-40) into the oil filter.

10)Install oil filter hoses (1).

3 Oil filter: 13 ± 2 Nm {1.33 ± 0.2 kgm} • Tighten the oil filter by three quaters turns after its sealing face touches the seat.

37.Alternator 1) Install bracket (2).

3 Mounting bolt: 43 ± 6 Nm {4.38 ± 0.61 kgm} 2) Tighten bracket (3) lightly.

3) Install alternator (1) to brackets (2) and (3).

3 Mounting bolt (4): 98 to 123 Nm {9.99 to 12.5 kgm} 3 Mounting bolt (5): 43 ± 6 Nm {4.38 ± 0.61 kgm}

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38.Belt tensioner Install belt tensioner (2) using mounting bolt (1).

3 Mounting bolt:

3) Install wiring harness bracket (3).

3 Mounting bolt: 43 ± 6 Nm {4.38 ± 0.61 kgm}

43 ± 6 Nm {4.38 ± 0.61 kgm}

39.Pulley and lifting plate 1) Install lifting plate (4) using mounting bolt (5).

3 Mounting bolt:

40.Vibration damper Install vibration damper (1).

3 Mounting bolt: 200 ± 10 Nm {20.4 ± 1.02 kgm}

43 ± 6 Nm {4.38 ± 0.61 kgm}

41.Removal from engine repair stand 2) Install pulley (1) and wiring harness bracket (2) to lifting plate (4).

3 Mounting bolt: 43 ± 6 Nm {4.38 ± 0.61 kgm}

1) Sling engine assembly (2) and disconnect it from tool A (repair stand).

4 Engine assembly: Approx. 880 kg (Weight depends on the applicable machine model) 2) Remove tool B (adapter) from engine assembly (2).

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3) Place and fix engine assembly (2) on stable engine stand [1].

4) Apply adhesive to the guide of dipstick pipe (1), then drive it in.

2 Mounting portion of dipstick tube: Adhesive (LT-4)

43.Intake manifold (intake cover) 1) Install new gasket (4) to intake manifold cover (5).

2) When intake heater (2) and intake connector (3) are removed from intake manifold (1), install them according to the following procedure.

1] Install in the order of intake connector (3), gasket (7), intake heater (2), gasket (7), plate (8), gasket (7) and intake manifold (1).

2] Tighten them using the mounting bolts. a Tighten the bracket together with them.

3 Mounting bolt: 24 ± 4 Nm {2.45 ± 0.41 kgm}

42.Engine oil pressure switch connector and plug Install engine oil pressure switch connector (1) to the cylinder block.

3 Engine oil pressure switch connector: 18 ± 3 Nm {1.84 ± 0.31 kgm}

3) Install intake manifold (intake cover) (1).

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3 Mounting bolt: 24 ± 4 Nm {2.45 ± 0.41 kgm} 4) Install sandwich clamp (6) for the highpressure pipe to intake manifold (1).

3 Mounting bolts (6) and (7): 24 ± 4 Nm {2.45 ± 0.41 kgm} 3 Mounting nut (10): 10 ± 2 Nm {1.02 ± 0.2 kgm}

3 Mounting bolt: 24 ± 4 Nm {2.45 ± 0.41 kgm}

• Wiring harness clamps (11), (12) and (13) 3 Mounting nuts (11), (12) and (13): 10 ± 2 Nm {1.02 ± 0.2 kgm}

44.Wiring harness assembly Install the connector, clamp and band, then install the wiring harnesses assembly.

• Coolant temperature sensor connector (2)

• Exhaust manifold pressure sensor connector (3) • Wiring harness clamp (4) 3 Mounting bolt (4): 24 ± 4 Nm {2.45 ± 0.41 kgm}

• • • • •

Ambient pressure sensor connector (14) Supply pump connector (15) Wiring harness connectors (16): three places Wiring harness clamp (17) Band (18) 3 Mounting bolt (15): 24 ± 4 Nm {2.45 ± 0.41 kgm} 3 Mounting nut (17): 24 ± 4 Nm {2.45 ± 0.41 kgm}

• Bands (5), (8) and (9) • Wiring harness clamps (6), (7) and (10) 114E-5 SERIES

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• Charge (boost) pressure and temperature sensor connector (19) • Common rail pressure sensor connector (20) • Wiring harness clamp (21) • Wiring harness bracket (22)

7) Install EGR orifice temperature sensor connector (8) to EGR valve piping (3).

3 Mounting bolt (21): 10 ± 2 Nm {1.02 ± 0.2 kgm} 3 Mounting bolt (22): 24 ± 4 Nm {2.45 ± 0.41 kgm}

8) Install hoses (9) and (10) from KVGT to EGR valve (1).

• Hose (9): KVGT control hydraulic circuit • Hose (10): KVGT drive hydraulic circuit 3 Sleeve nut (hose (9)): 25 ± 1.5 Nm {2.55 ± 0.15 kgm} 3 Sleeve nut (hose (10)): 45.EGR valve 1) Install the gasket to intake manifold (2), and install EGR valve (1).

15 ± 1 Nm {1.53 ± 0.1 kgm} 9) Install wiring harness connectors (11), (12) and (13) to EGR valve (1).

• Connector (11): KVGT position sensor • Connector (12): KVGT speed sensor • Connector (13): Connector box

3 Mounting bolt: 43 ± 6 Nm {4.38 ± 0.61 kgm} 2) Install the hose part of EGR valve piping (3) to tube (4).

3) Install the gasket and install EGR piping (3) to EGR valve (1).

3 Mounting bolt: 24 ± 4 Nm {2.45 ± 0.41 kgm} 4) Install bracket (5) to the stud bolt.

46.Fuel lift pump and engine controller cooling plate 1) Install fuel lift pump (3) to engine controller cooling plate (2).

3 Mounting bolt: 10 ± 2 Nm {1.02 ± 0.2 kgm}

3 Mounting nut: 24 ± 4 Nm {2.45 ± 0.41 kgm} 5) Tighten hose clamp (6) permanently.

3 Hose clamp: 10.5 ± 0.5 Nm {1.07 ± 0.05 kgm} 6) Install wiring harness (7) to bracket (5).

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a When installing ground cable (4), provide a clearance between it and engine controller (1).

3 Mounting nut: 24 ± 4 Nm {2.45 ± 0.41 kgm}

2) Lightly push valve (4) of the check valve from the arrow side to check whether it moves smoothly and the sealing face closes appropriately.

3) Install bracket (6).

3 Mounting nut: 10 ± 2 Nm {1.02 ± 0.2 kgm} 4) Install wiring harness (5) to the engine controller. a Wiring harness (5) is locked with hexagonal socket head bolt (7) (4 mm).

3 Mounting bolt: 3 ± 1 Nm {0.31 ± 0.1 kgm} 3) Install engine controller cooling plate (2) and bracket (1).

3 Bracket mounting bolt: 43 ± 6 Nm {4.38 ± 0.61 kgm}

5) Fix wiring harness (5) using bolt (8).

47.Engine controller 1) Install engine controller (1) to engine controller cooling plate (2) using mounting bolts (3).

3 Mounting bolt (8): 24 ± 4 Nm {2.45 ± 0.41 kgm} 6) Install wiring harness (5) to bracket (9).

7) Install Ne (crankshaft) speed sensor connector (10).

8) Install engine oil pressure switch connector (11).

3 Mounting bolt: 24 ± 4 Nm {2.45 ± 0.41 kgm} 2) Install ground cable (4).

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9) Install clamp (12) for securing wiring harness (5).

3 Mounting bolt: 24 ± 4 Nm {2.45 ± 0.41 kgm} 10)Install clamp (14) for securing wiring harness (5), together with bracket (13).

3 Mounting bolt (clamp (14)):

3) 4) 5) 6)

Install fuel hose (3).

Install fuel hose (2).

Install fuel hose (7).

Install bracket (5) to bundle fuel hoses (2), (3) and (4).

3 Mounting bolt: 43 ± 6 Nm {4.38 ± 0.61 kgm}

24 ± 4 Nm {2.45 ± 0.41 kgm} 3 Mounting bolt (bracket (15)): 43 ± 6 Nm {4.38 ± 0.61 kgm} 11)Install wiring harness (5) to bracket (6).

12)Install fuel lift pump connector (16).

13)Install Bkup (cam) speed sensor connector (17).

7) Install fuel filter (1) together with bracket (6).

8) Install fuel hoses (2) and (3) to fuel filter (1).

48.Fuel filter and hose 1) Install bracket (8) using bolt (9).

3 Mounting bolt: 43 ± 6 Nm {4.38 ± 0.61 kgm} 2) Install fuel hose (4).

49.Blowby hose and oil filler port 1) Install blowby hose (1).

2) Install hose clamps (3) and (4). a Install them in such a way that the wiring harness clamp comes to the outside.

3 Mounting bolt: 24 ± 4 Nm {2.45 ± 0.41 kgm}

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9) Install tube clamps (9) (three places).

3 Mounting bolt: 24 ± 4 Nm {2.45 ± 0.41 kgm}

3) Install oil filler port inlet connector (2).

4) Install blowby hose (1) to oil filler port inlet connector (2). a Insert it until a clicking sound of lock (L) is heard.

5) Tighten hose clamp (5).

6) Install tube (6) which is used between the EGR valve and boost pump.

3 Sleeve nut : 25 ± 1.5 Nm {2.55 ± 0.15 kgm} 7) Install tube clamps (7) (three places).

3 Mounting bolt:

10)Install oil filler port (10) to oil filler port inlet connector (2), then tighten tube clamp (11).

11)Tighten hose clamp (12) for oil filler port (10).

50.Alternator belt Install alternator belt (1). a Attach a wrench to portion (A) (width across flats: 12.7 mm) of tensioner assembly (2), and rotate it in direction opposite to the winding-up direction.

24 ± 4 Nm {2.45 ± 0.41 kgm} k Rotate

the wrench after making sure it is securely attached to portion (A) of tensioner assembly (2). (If you try to rotate the wrench before it is securely attached due to the strong spring force of tensioner assembly (2), it can disengage and cause serious physical injuries.)

k After

installing alternator belt (1), return tensioner assembly (2) slowly and carefully.

k Take

8) Install tube (8) which is used between the EGR valve and oil filler port inlet connector.

care not to get your fingers caught between the pulley and alternator belt (1) during work.

3 Sleeve nut: 25 ± 1.5 Nm {2.55 ± 0.15 kgm} 114E-5 SERIES

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a Be sure to maintain a minimum clearance of 15 mm between wiring harness (3) and alternator belt (1).

a Clean and degrease the engine and the parts around it in advance so that you can easily be able to find fuel leakage.

51.Tightening torque of sensors When reinstalling or replacing the sensors, tighten them to the following torque.

Tightening torque 18 ± 3 Nm {1.84 ± Coolant temperature sensor 0.31 kgm} 18 ± 3 Nm {1.84 ± Engine oil pressure switch 0.31 kgm} 9 ± 2 Nm {0.92 ± 0.2 Ne (crankshaft) speed kgm} sensor 9 ±2 Nm {0.92 ± 0.2 Bkup (camshaft) speed kgm} sensor 8 ± 2 Nm {0.82 ± 0.2 Ambient pressure sensor kgm} 3 ± 1 Nm {0.31 ± 0.1 Charge (boost) pressure kgm} and temperature sensor Exhaust manifold pressure 20 ± 3 Nm {2.04 ± 0.31 kgm} sensor 20 ± 3 Nm {2.04 ± EGR orifice temperature 0.31 kgm} sensor 10 ± 2 Nm {1.02 ± 0.2 Fuel level sensor kgm} 43 ± 6 Nm {4.38 ± Fuel sensor bracket 0.61 kgm} Sensor name

52.Check for fuel leakage a If supply pump (1), common rail (2), or highpressure pipe is removed or installed, check for fuel leakage according to the following procedure after assembling the engine.

1) Spray color checker (developer) over the joint of the supply pump, common rail, injector and high-pressure pipe.

2) Run the engine at speed below 1,000 rpm and stop it after its speed is stabilized.

3) Stop the engine and check the fuel piping and compornent for fuel leakage. a Check mainly around the high-pressure circuit parts coated with the color checker for fuel leakage. a If any fuel leakage is detected, repair it and perform testing again from Step 2).

4) Run the engine and keep its speed at low idle.

5) Stop the engine and check the fuel piping and compornent for fuel leakage. a Check mainly around the high-pressure circuit parts coated with the color checker for fuel leakage. a If any fuel leakage is detected, repair it and perform testing again from Step 2).

6) Run the engine and keep its speed at high idle.

7) Stop the engine and check the fuel piping and compornent for fuel leakage. a Check mainly around the high-pressure circuit parts coated with the color checker for fuel leakage. a If any fuel leakage is detected, repair it and perform testing again from Step 2).

8) Run the engine at full speed and apply a load on the engine. a When checking while the components to be checked are mounted on the machine, stall the torque converter or relieve the main pump.

9) Stop the engine and check the fuel piping and compornent for fuel leakage.

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a Check mainly around the high-pressure circuit parts coated with the color checker for fuel leakage. a If any fuel leakage is detected, repair it and perform testing again from Step 2). a If no fuel leakage is detected, the inspection process is completed.

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Removal and installation procedure of supply pump unit alone

(ENG114-AD70-924-

K-00-A)

Removal

(ENG114-AD70-520-K-00-A)

1. Disconnect wiring harness connector (1).

2. Disconnect wiring harness clamp (2). [*1]

3. Disconnect fuel hoses (4), (5) and (6) from supply pump (3).

4. Remove fuel spray prevention cap (7).

5. Loosen sandwich clamp (8) and remove bracket (9) mounting bolt.

6. Remove high-pressure pipe (10) together with sandwich clamp (8) and bracket (9).

7. Disconnect tube (11) from supply pump (3).

10.After removing the washer, tighten nut (13) again.

11.Rotate the crankshaft in the normal direction to set stamp (a) of supply pump drive gear (15) to the top, and set the No. 1 cylinder to the compression top dead center (TDC).

12.Install tool P to the front gear cover using bolt [1] (M8 x 1.25).

8. Remove cap (12) of the front gear cover.

9. Remove nut (13) and washer (14).

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13.Remove four nuts (16) and bolts (17) and (18), and remove bracket (19).

14.Alternately tighten bolts [1] of tool P, which is installed in Step 12, and disconnect the supply pump drive shaft from the supply pump drive gear.

15.After removing tool P, remove supply pump (3).

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4. Install a new O-ring (22) to the supply pump lubrication port.

5. Using contact cleaner, clean the contact surface between the periphery of supply pump drive shaft and the inner diameter side of the supply pump gear.

6. Before installing the supply pump, check that the contact surface between the periphery of the supply pump drive shaft and the inner diameter side of the supply pump gear is dry and free from foreign matter.

Installation

(ENG114-AD70-720-K-00-A)

Install the supply pump according to the following procedure.

1. Rotate the crankshaft in the normal direction to set stamp (a) of the supply pump drive gear to the top, and set the No. 1 cylinder to the compression top dead center (TDC).

7. Align dowel pin (20) of supply pump drive shaft (23) to key slot (b) of supply pump gear (15) and push it into the slot.

2. Before installing the supply pump, check that dowel pin (20) of the supply pump drive shaft is not damaged. a If the dowel pin is damaged, replace the supply pump and supply pump gear.

8. Install washer (14) to supply pump drive shaft (23), and tighten nut (13) temporarily.

3. Install a new O-ring (21) to the supply pump flange.

2 O-ring (21): Engine oil (EO15W-40)

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9. Tighten nut (16) temporarily until its looseness is eliminated, then fix supply pump (3).

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2 Mounting nut (16): Adhesive (LT-2) 10.Tighten supply pump mounting nut (16).

3 Mounting nut (16): 43 ± 6 Nm {4.38 ± 0.61 kgm} 11.Tighten bracket (19) temporarily using bolts (17) and (18).

12.Tighten cylinder head side mounting bolt (17).

3 Mounting bolt (17): 43 ± 6 Nm {4.38 ± 0.61 kgm} 13.Tighten supply pump flange side mounting bolt (18).

3 Mounting bolt (18): 77 ± 12 Nm {7.85 ± 1.22 kgm}

16.High-pressure pipe k Do

not use high-pressure pipes with bending modification.

k Be

sure to use the genuine high-pressure pipe fixing clamp and observe the tightening torque.

k Install

each high-pressure pipe and wiring harness at least 10 mm apart from each other.

14.Tighten nut (13).

3 Mounting nut: 180 ± 13 Nm {18.4 ± 1.33 kgm}

a When installing each high-pressure pipe, check the taper seal of its joint (portion (a): part of 2 mm from the end) for visible lengthwise slit (b) and spot (c), and check portion (d) (end of taper seal: part at 2 mm from the end) for stepped-type wear caused by fatigue that is able to be felt with your finger nail. If any of those defects exist, they may cause fuel leakage. In this case, replace the high-pressure pipe.

15.Install cap (12) of the front gear cover.

1) Install high-pressure pipe (10) between the supply pump and common rail. a Install the high-pressure pipe together with sandwich clamp (8) and tighten the bracket (9) lightly.

3 Sleeve nut : 37 ± 4 Nm {3.77 ± 0.41 kgm}

50-72

114E-5 SERIES

50 Disassembly and assembly Disassembly and assembly

2) Loosen sandwich clamp (8) for the highpressure pipes.

3) Tighten bracket (9) of sandwich clamp (8) fixing the high-pressure pipe.

3 Mounting bolt: 24 ± 4 Nm {2.45 ± 0.41 kgm} 4) Tighten sandwich clamp (8).

3 Mounting bolt: 6 Nm {0.61 kgm} 5) Install two fuel spray prevention caps (7). a Set the slits of each bellows out and down. a The fuel spray prevention caps are installed so that fuel does not spout over the hot parts of the engine and catch fire when it leaks for some reason.

6) Install tube (11).

3 Joint bolt: 24 ± 4 Nm {2.45 ± 0.41 kgm}

Carry out the following installation in the order reverse to removal. [*1] Wiring harness clamp (2) 3 Mounting bolt: 24 ± 4 Nm {2.45 ± 0.41 kgm}

114E-5 SERIES

50-73

50 Disassembly and assembly Disassembly and assembly

Engine front oil seal replacement procedure Removal

(ENG114-A350-924-K-00-A)

(ENG114-A350-520-K-00-A)

1. Remove alternator belt (1). a Attach a wrench to portion (A) (width across flats: 12.7 mm) of tensioner assembly (2), and rotate the wrench in the direction opposite to the winding-up direction to decrease alternator belt (1) tension. k Rotate

the wrench after making sure it is securely attached to portion (A) of tensioner assembly (2). (If you try to rotate the wrench before it is securely attached due to the strong spring force of tensioner assembly (2), it can disengage and cause serious physical injuries.)

2) Remove front oil seal carrier assembly (7) from front cover (5).

k After

removing alternator belt (1), return tensioner assembly (2) slowly and carefully.

k Take

care not to get your fingers caught between the pulley and alternator belt (1) during work.

3) Remove front oil seal (8).

2. Remove five bolts (4) and remove vibration damper (3).

Installation

(ENG114-A350-720-K-00-A)

1. Wipe off foreign matters adhering to crankshaft flange (A) using a clean cloth.

2. Set tool T on front oil seal (8) from pilot [1] side. a Pilot [1] is a plastic part provided inside the front seal. Since it functions as the guide tool when installing the crankshaft, you must not remove it from the front oil seal.

3. Remove the front oil seal according to the following procedure.

1) Remove dust seal (6) from front oil seal carrier assembly (7).

50-74

114E-5 SERIES

50 Disassembly and assembly Disassembly and assembly

3 Mounting nut: 8 ± 1 Nm {0.82 ± 0.1 kgm} 8. Install dust seal (6). a Push in the dust seal until it reaches the front oil seal.

3. Install front oil seal (8) from inside of front oil seal carrier (7).

4. Apply pilot [1] to the crankshaft and push it by hand into the crankshaft together with front oil seal carrier (7).

5. Remove pilot [1].

9. Install vibration damper (3).

3 Mounting bolt (4): 200 ± 10 Nm {20.4 ± 1.02 kgm}

6. Apply liquid gasket to the following parts and install front oil seal carrier (7).

• All circumferences (a) of inside of front oil seal carrier (7) • Threaded portion (b) of bolt (9) and contact surface (c) of front oil seal carrier • Threaded portion (d) of nut (10) 2 Portions (a), (b), (c) and (d) indicated in the figure: Liquid gasket (LG-7)

10.Alternator belt Install alternator belt (1). a Attach a wrench to portion (A) (width across flats 12.7 mm) of tensioner assembly (2) and rotate it in the direction opposite to the winding-up direction. k Rotate

the wrench after making sure it is securely attached to portion (A) of tensioner assembly (2). (If you try to rotate the wrench before it is securely attached due to the strong spring force of tensioner assembly (2), it can disengage and cause serious physical injuries.)

k After

installing alternator belt (1), return tensioner assembly (2) slowly and carefully.

k Take

7. Tighten mounting nut (10) of front oil seal carrier (7) in the sequence shown in the figure [1] to [5].

114E-5 SERIES

care not to get your fingers caught between the pulley and alternator belt (1) during work.

50-75

50 Disassembly and assembly Disassembly and assembly

a Be sure to maintain a minimum clearance of 15 mm between wiring harness (3) and alternator belt (1).

50-76

114E-5 SERIES

50 Disassembly and assembly Disassembly and assembly

Engine rear oil seal replacement procedure Removal

(ENG114-A510-924-K-00-A)

(ENG114-A510-520-K-00-A)

1. Remove mounting bolts (2), set guide bolts and lift off flywheel (1).

4 Flywheel assembly: 60 kg

5. Remove rear oil seal (7) from rear cover (6).

2. Sling flywheel housing (4), remove mounting bolts (3) and lift off flywheel housing (4).

4 Flywheel housing: 60 kg

Installation

(ENG114-A510-720-K-00-A)

1. Clean, degrease, and dry the gasket faces against the rear cover and cylinder block.

2. Clean, degrease, and dry the seal lip sliding surface (peripheral surface of the crankshaft).

3. Remove four oil pan mounting bolts (5), eight housing mounting bolts (8) and remove rear cover (6). a Take care when separating the rear cover from the oil pan gasket not damage the gasket. a Insert a feeler gauge between the rear cover and oil pan gasket, then move the gauge back and forth to separate them. a If the oil pan gasket is damaged, remove the oil pan and replace the gasket. [*1] 6 Engine oil: Approx. 24 l 4. Remove seal (11) from rear cover (6).

114E-5 SERIES

a Check that the end corner and lip sliding surface of the crankshaft are free from flaws, burrs, sharp fins, rusts, etc.

3. Apply neutral detergent to the periphery of the rear oil seal. a Portion (P) is a plastic part provided inside the rear oil seal. Since it functions as the pilot (guide tool) when installing the crankshaft, you must not remove it from the rear oil seal.

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50 Disassembly and assembly Disassembly and assembly

4. Install rear oil seal (7) to rear cover (6).

2) Apply a little more thicker liquid gasket to two hatched portions (c) in the figure.

2 Hatched portions (c): Liquid gasket (LG-7)

5. Using alignment tool (positioning tool) (A) attached to the engine rear seal, push rear oil seal (7) into rear cover (6) up to a proper depth.

6. Remove alignment tool (A).

7. After Install guide pin [2] and gasket (10), apply pilot (P) to crankshaft (9) and push it by hand into crankshaft (9) together with rear cover (6). a Cut gasket (10) so that its protrusion (d) from the oil pan surface is 0.25 mm or less. a Take care so that the cut gasket may not fall in the engine. a Adjust rear cover (1) and both sides of oil pan rail to the same height. a Horizontal direction: Max.0.00 Âą 0.10 mm

Apply liquid gasket according to the following procedure.

1) Apply liquid gasket to the area in the figure being enclosed by a heavy line at the bottom face of rear cover (6).

a Vertical direction: Max. 0.150 mm 8. Remove the pilot (P).

a Apply a continuous bead of liquid gasket 3 mm in diameter to the area enclosed by a heavy line.

2 Rear cover bottom face: Liquid gasket (LG-7)

50-78

114E-5 SERIES

50 Disassembly and assembly Disassembly and assembly

a Facial runout: Max. 0.38 mm a Radial runout: Max. 0.25 mm 15.Install seal (11) to seal cover (6).

9. Install alignment tool (A) again and check that rear oil seal (7) is inserted to a proper depth. a Leave alignment tool (A) installed without trying to remove it.

10.Tighten oil pan mounting bolt (5) temporarily.

11.Remove guide pin [2], which is installed in Step 8, and tighten eight rear cover mounting bolts (8) in the sequence shown in the figure [1] to [8].

3 Mounting bolt: 13 ± 2 Nm {1.33 ± 0.2 kgm}

16.Apply a continuous bead of liquid gasket 1 to 3 mm in diameter to the mounting flanged surface of the flywheel housing and around the mounting bolt holes.

2 Mounting flanged surface and around mounting bolt holes: Liquid gasket (LG-7) 17.Tighten temporarily flywheel housing (4) using mounting bolt (3).

4 Flywheel housing: 60 kg 18.Tighten flywheel housing mounting bolts (3) in the sequence shown in the figure [1] to [12].

3 Mounting bolt: 77 ± 12 Nm {7.85 ± 1.22 kgm}

19.After installing the flywheel housing, measure the radial runout and facial runout with tool L. a Radial runout: Max. 0.20 mm 12.Tighten oil pan mounting bolt (5) permanently.

3 Mounting bolt: 24 ± 4 Nm {2.45 ± 0.41 kgm} 13.Remove alignment tool (A).

14.Measure facial runout and radial runout of the rear oil seal to the crankshaft.

114E-5 SERIES

a Facial runout: Max. 0.20 mm • Measurement of radial runout 1) Install tool L to the crankshaft end.

2) Set the probe of the dial gauge perpendicular to the spigot joint portion of the flywheel housing.

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50 Disassembly and assembly Disassembly and assembly

3) Set the dial gauge reading to “zero”, rotate the crankshaft by one turn, and measure the difference between the indicated lowest and highest values. a After the crankshaft is rotated by 1 turn, check that the dial gauge indicates the value at the start of rotation.

21.Secure the flywheel and flywheel housing using the lock plate, combination wrench [3] and such, and tighten the bolts in the sequence shown in the figure [1] to [8].

3 Mounting bolt: 137 ± 7 Nm {14.0 ± 0.71 kgm}

• Measuring facial runout 1) Similarly to measurement of the radial runout, set the probe of the dial gauge perpendicular to the end face of the flywheel housing. a When measuring, bring the crankshaft to the front or rear side so that an error does not be caused by the end play.

2) Set the dial gauge reading to “zero”, rotate the crankshaft by one turn, and measure the difference between the indicated lowest and highest values.

22.After installing the flywheel housing, measure the radial runout and facial runout using tool L. a Radial runout: Max. 0.13 mm a Facial runout: Max. 0.20 mm

20.Install the guide bolt and then install flywheel (1). a Apply a continuous bead of liquid gasket 1 to 3 mm in diameter around the bolt holes on the crankshaft mounting surface (eight places).

2 Flywheel mounting surface: Liquid gasket (LG-7) 4 Flywheel: 60 kg

50-80

• Measurement of radial runout 1) Set tool L to the flywheel housing.

2) Bring the dial gauge probe into contact with faucet joint portion (a) or the outer perimeter surface of the flywheel at a right angle.

3) Give the flywheel one turn and measure the largest difference among the values indicated by the dial gauge. a Give the flywheel one turn and check that the dial gauge indicates the same value as the one at the start of rotation.

• Measuring facial runout 1) As in the case of measurement of radial runout, bring the dial gauge probe into contact with end surface (b) near the outer perimeter of the flywheel at a right angle. a When measuring, bring the crankshaft to the front or rear side so that an error does not be caused by the end play.

114E-5 SERIES

50 Disassembly and assembly Disassembly and assembly

2) Give the flywheel one turn and measure the largest difference among the values indicated by the dial gauge.

4. Insert the gasket to the end flange and install suction tube (15).

2 Flange: Liquid gasket (LG-7) 3 Flange mounting bolt: 10 Âą 2 Nm {1.02 Âą 0.2 kgm}

Carry out the following installation in the order reverse to remonal. [*1] When the oil pan is removed for replacement of the gasket, install the oil pan according to the following procedure.

1. Apply liquid gasket to the clearance e range between the cylinder block and gear housing, and between the cylinder block and rear cover.

5. Apply liquid gasket to the hatched portion of the bed plate side mating face and install gasket (16).

2 Gasket (mating face of bed plate): Liquid gasket (LG-7)

2 Clearance e range: Liquid gasket (LG-7)

2. Install guide pin [4] to cylinder block (12) and install gasket (13) to them.

6. Apply liquid gasket to the entire circumference of oil pan (17) at the gasket side mating face.

2 Oil pan: Liquid gasket (LG-7) 3. Install bed plate (14).

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50-81

50 Disassembly and assembly Disassembly and assembly

7. Install oil pan (17) using mounting bolt (5).

8. Tighten oil pan mounting bolts (5) in the sequence shown in the figure [1] to [32].

3 Mounting bolt: 24 Âą 4 Nm {2.4 Âą 0.4 kgm}

50-82

114E-5 SERIES

SHOP MANUAL

ENGINE 114E–5 SERIES Model

Serial Number

114E–5 SERIES

60 Maintenance standard 6 60 Maintenance standard

114E-5 SERIES

60-1

60 Maintenance standard Table of contents

Table of contents

(ALL-0310-002-A-00-A)

60 Maintenance standard................................................................................................................... 60-1 Table of contents ........................................................................................................................ 60-2 Intake and exhaust system parts .................................................................................................. 60-3 KVGT.................................................................................................................................. 60-3 Engine main body parts............................................................................................................... 60-4 Cylinder head ...................................................................................................................... 60-4 Cylinder block ...................................................................................................................... 60-6 Cylinder liner ....................................................................................................................... 60-8 Crankshaft......................................................................................................................... 60-10 Piston ............................................................................................................................... 60-12 Connecting rod .................................................................................................................. 60-13 Vibration damper................................................................................................................ 60-15 Timing gear ....................................................................................................................... 60-16 Camshaft .......................................................................................................................... 60-17 Valve and valve guide......................................................................................................... 60-19 Rocker arm........................................................................................................................ 60-21 Flywheel............................................................................................................................ 60-23 Lubrication system.................................................................................................................... 60-25 Oil pump ........................................................................................................................... 60-25

60-2

114E-5 SERIES

60 Maintenance standard KVGT

Intake and exhaust system parts KVGT

(ENG107-A900-001-K-00-A)

(ENG114-AA10-034-K-00-A)

KVGT: Abbreviation for KOMATSU Variable Geometry Turbocharger

No.

Item Radial play (Play in radial 1 direction)

0.254 to 0.356

End play (play in axial 2 direction)

0.025 to 0.127

114E-5 SERIES

Criteria

Unit: mm Remedy Replace KVGT as an assembly (including hydraulic actuator, KVGT position sensor)

60-3

60 Maintenance standard Cylinder head

Engine main body parts Cylinder head

60-4

(ENG107-R402-001-K-00-A)

(ENG114-A100-034-K-00-A)

114E-5 SERIES

60 Maintenance standard Cylinder head

No.

Item

Distortion of mounting 1 surface to cylinder block

Tightening torque for cylinder head mounting bolt (apply engine oil to threads 2 and seat surface)

Using limit of nominal length for cylinder head mounting bolt.

Criteria End-to-End

Max.: 0.203

Side-to-Side

Max.: 0.075

Procedure 1st stage 2nd stage 3rd stage 4th stage 5th stage 6th stage

Target (Nm {kgm}) 50{5.1} 150{15.3} Loosen 360 deg 115 {11.7} 115 {11.7} retighten 120 deg Less than 162.6

3 Protrusion of injector nozzle

2.43 to 3.18

Tightening torque for injector 4 holder mounting bolt Tightening torque for head 5 cover mounting bolt

Target (Nm {kgm}) 9.8 {1.0}

Unit: mm Remedy Repair by grinding or replace cylinder head

Tighten and retighten

Replace cylinder head mounting bolt Replace nozzle or gasket Tighten

12{1.2}

* : However, see "Disassembly and assembly" for the assembly procedure.

114E-5 SERIES

60-5

60 Maintenance standard Cylinder block

Cylinder block

60-6

(ENG114-A300-034-K-00-A)

114E-5 SERIES

60 Maintenance standard Cylinder block

No. 1

Item strain of cylinder mounting face

Thickness of main bearing metal Inside diameter of cam 3 bushing mounting hole Inside diameter of cam 4 bushing 2

Tightening torque for main 5 cap mounting bolt (apply engine oil to threads) Tightening torque for oil pan 6 mounting bolt Tightening torque for 7 crankshaft pulley mounting bolt

114E-5 SERIES

Criteria End-to-End

Max. 0.075

Side-to-Side

Max. 0.075 3.446 to 3.454 Max. 64.013

Max. 60.120 Target (Nm {kgm}) Procedure 1st stage 60 {6.1} 2nd stage retighten 120 deg.

Target (Nm {kgm}) 28 {2.8}

Unit: mm Remedy Repair by grinding or replace Replace metal Correct or replace block Replace cam bushing Tighten and retighten

Tighten

200 {20.4}

60-7

60 Maintenance standard Cylinder liner

Cylinder liner

(ENG114-A340-034-K-00-A)

Unit: mm No.

Check item

Inside diameter of cylinder liner 1 Roundness of cylinder liner Taper of cylinder liner 2 Protrusion of cylinder liner 3

Outside diameter of cylinder liner

Inside diameter of cylinder 4 liner bore in cylinder block

60-8

Criteria 114.000 to 114.040 Repair limit 0.04 Repair limit 0.04 0.026 to 0.122 130.938 to 130.958 130.900 to 130.950

Remedy

Repair cylinder liner Replace cylinder liner or cylinder block Repair cylinder liner Replace cylinder liner or cylinder block 114E-5 SERIES

60 Maintenance standard Cylinder liner

Unit: mm No.

Check item

Clearance between cylinder 5 liner and cylinder block

114E-5 SERIES

Criteria

Remedy

Min. 0.229

60-9

60 Maintenance standard Crankshaft

Crankshaft

60-10

(ENG114-A530-034-K-00-A)

114E-5 SERIES

60 Maintenance standard Crankshaft

No.

Check item

1 End play

Outside diameter of main journal 2

0.107 to 0.360 Standard 0.25 undersize 0.50 undersize 0.75 undersize 1.00 undersize

Roundness of main journal Taper of main journal Clearance of main journal

Standard size 98.019 97.769 97.519 97.269 97.019 Max. 0.0064 Max. 0.013

3

Roundness of crankshaft pin journal Taper of crankshaft pin journal Clearance of crankshaft pin journal

114E-5 SERIES

Tolerance

Âą0.013

Standard

76.013

0.25 undersize

75.763

0.50 undersize 0.75 undersize 1.00 undersize

75.513 75.263 75.013

Use undersize journal or replace

Replace main bearing metal

0.051 to 0.111 Standard size

Outside diameter of crankshaft pin journal

Unit: mm Remedy Replace thrust bearing metal

Criteria

Tolerance

Âą0.013

Use undersize journal or replace

Max. 0.0064 Max. 0.013 0.024 to 0.100

Replace connecting rod bearing metal

60-11

60 Maintenance standard Piston

Piston

No.

(ENG114-A580-034-K-00-A)

Check item

Clearance at piston ring end 1 gap Outside diameter of piston 2 pin 3

Inside diameter of piston pin hole

60-12

Top ring 2nd ring Oil ring

Criteria 0.30 to 0.40 0.70 to 1.00 0.30 to 0.60 44.997 to 45.003

Unit: mm Remedy Replace piston ring or piston

Peplace piston or piston pin

45.006 to 45.012

114E-5 SERIES

60 Maintenance standard Connecting rod

Connecting rod

(ENG114-A590-034-K-01-A)

a The material of connecting rod metal of undersize is not the same between top and bottom. The metal at upper side is marked "UPR" to identify top or bottom.

114E-5 SERIES

60-13

60 Maintenance standard Connecting rod

Unit: mm No.

Item

Criteria

Inside diameter of 1 connecting rod bushing (When installing bushing) 2 3 4

5

6

Clearance of connecting rod metal Thickness of connecting rod metal Inside diameter of mounting hole of connecting rod metal Tightening torque of connecting rod cap mounting bolt (Apply engine oil to bolt threaded part and nut seat surface.)

Clearance of connecting rod metal

45.023 to 45.035

0.024 to 0.10

Remedy Replace bushing (Spare part is half finished.)

2.457 to 2.469

Replace connecting rod metal

80.987 to 81.013

Replace connecting rod

Procedure 1 stage 2 stages

Target (Nm {kgm}) 30 {3.1} 70 {7.1}/ 50 {5.1} ( *1)

3 stages

Retighten 60 °deg.

0.130 to 0.275

Tightening and retightening

Replace connecting rod

*1: Indicates the value of HB335–1, HB335LC–1, HB365–1, HB365LC–1.

60-14

114E-5 SERIES

60 Maintenance standard Vibration damper

Vibration damper

No. ― ―

(ENG114-A5E0-034-K-00-A)

Item Tightening torque of vibration damper Convex and concave of vibration damper

114E-5 SERIES

Criteria Target (Nm {kgm}) 200 {20.4} Free from convex and concave

Unit: mm Remedy Tighten and retighten Replace

60-15

60 Maintenance standard Timing gear

Timing gear

No. ―

(ENG114-A5A0-034-K-00-A)

Item Backlash of each gear

60-16

A B C

Criteria Backlash of oil pump gear Backlash of camshaft gear Backlash of idler gear

Unit: mm Remedy 0.08 to 0.33 0.08 to 0.33 0.08 to 0.33

Replace

114E-5 SERIES

60 Maintenance standard Camshaft

Camshaft

114E-5 SERIES

(ENG114-A5G0-034-K-00-A)

60-17

60 Maintenance standard Camshaft

No.

Item

1 End play Outside diameter of 2 camshaft bearing journal Thickness of camshaft thrust 3 plate Tightening torque of 4 camshaft thrust place mounting bolt

60-18

59.962 to 60.013

Unit: mm Remedy Replace thrust plate Correct or replace

9.40 to 9.60

Replace

Criteria 0.10 to 0.36

Target (Nm {kgm}) 24 {2.4}

Tighten

114E-5 SERIES

60 Maintenance standard Valve and valve guide

Valve and valve guide

114E-5 SERIES

(ENG114-A700-034-K-00-A)

60-19

60 Maintenance standard Valve and valve guide

No.

Item Depression of valve in 1 cylinder head (A) 2 Thickness of valve rim (B)

3 Valve seat angle Outside diameter of valve stem 5 Diameter of valve guide bore Inside diameter of valve 6 insert bore

4

60-20

Unit: mm Remedy Replace valve or valve seat

Criteria 0.70 to 1.16 Intake side

Min. 2.06

Exhaust side Valve Intake side

Min. 1.65 Angle 30 deg.

Exhaust side

45 deg.

7.96 to 7.98 8.019 to 8.039 13.15 to 13.65

Repair limit Judge contact surface condition by vacuum test.

Replace valve

Replace valve or valve seat Replace cylinder head Correct

114E-5 SERIES

60 Maintenance standard Rocker arm

Rocker arm

(ENG114-A770-034-K-00-A)

No.

Item Outside diameter of rocker 1 arm shaft Diameter of rocker arm shaft 2 hole 3

Criteria Min. 24.950 Max. 25.013

Clearance between rocker arm shaft and rocker arm

Max. 0.063

Tightening torque for locknut 4 of rocker arm adjustment screw 5 Valve clearance (when cold) 6 Outside diameter of tappet 114E-5 SERIES

Target (Nm {kgm}) 24 {2.4} Valve Intake side Exhaust side

Repair limit 0.305 0.559 31.243 to 31.258

Unit: mm Remedy Replace rocker arm shaft Replace rocker arm Replace rocker arm or rocker arm shaft Tighten

Adjust Replace tappet

60-21

60 Maintenance standard Rocker arm

No.

Item Tightening torque of rocker 7 arm mounting bolt

60-22

Criteria Target (Nm {kgm}) 65 {6.6}

Unit: mm Remedy Tighten

114E-5 SERIES

60 Maintenance standard Flywheel

Flywheel

114E-5 SERIES

(ENG114-A560-034-K-00-A)

60-23

60 Maintenance standard Flywheel

No.

Item Radial runout of flywheel 1 housing Facial runout of flywheel 2 housing Tightening torque for 3 flywheel housing mounting bolt 4 Facial runout of flywheel

5 Radial runout of flywheel Tightening torque for flywheel mounting bolt 6 (apply engine oil to threads and seat surface)

60-24

Unit: mm Remedy

Criteria Repair limit: 0.20 Repair limit: 0.20 Target (Nm {kgm}) 77 {7.85} Flywheel

Limit

For clutch For torque converter

0.013/ f25.4 Diameter (actual measurement) x 0.0005 Repair limit: 0.13 Target (Nm {kgm}) 137 {14.0}

Reassemble, correct Tighten

Reassemble, correct

Tighten and retighten

114E-5 SERIES

60 Maintenance standard Oil pump

Lubrication system Oil pump

No. 1 2 3 4

(ENG114-AB50-034-K-00-A)

Item Clearance of rotor in axial direction Clearance between outer rotor and body Clearance between outer rotor and inner rotor Tightening torque of oil pump mounting bolt

114E-5 SERIES

(ENG107-AB00-001-K-00-A)

Criteria

Unit: mm Remedy

0.025 to 0.127 0.178 to 0.381

Replace oil pump

0.025 to 0.178 Target (Nm {kgm}) 24{2.4}

Tighten and retighten

60-25

INDEX

INDEX A

H

Aftercooler ................................................... 10-16 Alternator ..................................................... 10-80 Applicable machines ....................................... 01-6

Boost oil pump.............................................. 10-52

Handling equipment of fuel system devices..... 00-16 Handling of electrical equipment .................... 00-23 Handling of hydraulic equipment .................... 00-18 Handling of intake system parts ..................... 00-17 How to read electric wire code ....................... 00-31 How to read the shop manual ........................ 00-12 How to read this manual .................................. 50-3

C

I

Camshaft ..................................................... 60-17 Coating materials list....................................... 50-5 Components layout drawing ............................ 10-3 Connecting rod ............................................. 60-13 Conversion table .......................................... 00-50 Cooling system circuit diagram ...................... 10-71 Cooling system parts layout drawing .............. 10-70 Crankshaft ................................................... 60-10 Cylinder block.......................................10-38, 60-6 Cylinder head .......................................10-36, 60-4 Cylinder liner .................................................. 60-8

Important safety notice .................................... 00-5 Intake air heater............................................ 10-88 Intake and exhaust system circuit diagram ........ 10-6 Intake and exhaust system layout drawing ........ 10-5

D

L

Drive pulley .................................................. 10-73

List of abbreviation........................................ 00-45 Lubrication system circuit diagram.................. 10-50 Lubrication system parts layout drawing ......... 10-48

B

E EGR cooler .................................................. 10-23 EGR system circuit diagram .......................... 10-19 EGR system piping drawing........................... 10-17 EGR valve ................................................... 10-21 Engine controller........................................... 10-91 Engine front oil seal replacement procedure.... 50-74 Engine performance curve............................... 01-6 Engine rear oil seal replacement procedure .... 50-77 Engine wiring harness ................................... 10-89 Exhaust gas regulation.................................... 01-3 Explanation of terms for maintenance standard ...0014

F

K KCCV layout drawing .................................... 10-25 KCCV ventilator............................................ 10-28 KDPF .......................................................... 10-32 KVGT ....................................................10-9, 60-3

M Main filter ..................................................... 10-69 Main moving parts ........................................ 10-40 Method of disconnecting and connecting of push-pull type coupler ................................. 00-20

O Oil cooler ..................................................... 10-54 Oil filter ........................................................ 10-53 Oil pan ......................................................... 10-57 Oil pump ............................................ 10-51, 60-25

P

Flywheel ............................................ 10-47, 60-23 Front cover................................................... 10-45 Fuel system circuit diagram ........................... 10-60 Fuel system parts layout drawing ................... 10-58

Piston .......................................................... 60-12 Pre-filter ....................................................... 10-68 Precautions when performing operation.......... 00-34

G

R

General disassembly of engine ...................... 50-12 General view ................................................ 01-10

Regulator valve ............................................ 10-55 Removal and installation procedure of supply pump unit alone .......................................... 50-70 Rocker arm .................................................. 60-21

114E-5 SERIES

1

INDEX

Running-in standard and performance test standard....................................................... 20-9

S Safety valve ................................................. 10-56 Sensor......................................................... 10-97 Sketch of special tool .................................... 50-11 Special tool list ............................................... 50-9 Specifications ........................................ 01-6–01-7 Standard tightening torque table .................... 00-39 Standard value table for engine........................ 20-3 Starting motor............................................... 10-84 Supply pump ................................................ 10-64

T Thermostat................................................... 10-78 Timing gear ........................................ 10-44, 60-16

V Valve and valve guide ................................... 60-19 Valve system ................................................ 10-46 Vibration damper ................................ 10-43, 60-15

W Water pump ................................................. 10-77

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114E-5 SERIES

KOMATSU 114E-5 SERIES ENGINE Form No. SEN05537–01

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KOMATSU All Rights Reserved Printed in Japan 10–13