114

SEBM024603
DIESEL ENGINE
2004 All Rights Reserved 114 SERIES Printed in Japan 03-04(03)
00-1
(3)
CONTENTS
No. of page
01
GENERAL ..........................................................................................01-1
11
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD ............................................................11-1
12
TESTING AND ADJUSTING ..............................................................12-1
13
DISASSEMBLY AND ASSEMBLY ....................................................13-1
15
REPAIR AND REPLACEMENT OF PARTS ......................................15-1
00-2
114 SERIES
The affected pages are indicated by the use of the following marks. It is requested that necessary actions must be taken to these pages according to the list below.
Mark c z ( )
Indication Page to be newly added Page to be replaced Page to be deleted
Action required Add Replace Discard
Pages having no marks are not revised at this time.
LIST OF REVISED PAGES

Mark Pages Revision number Mark Pages Revision number Mark Pages Revision number Mark Pages Revision number Mark Pages Revision number
l
z z z z z z z z z z z z z z z z z z z z
z z z
z z z
00- 1 00- 2 00- 2-1 00- 2-2 00- 3 00- 4 00- 5 00- 6 00- 7 00- 8 00- 9 00-10 00-11 00-12 00-13 00-14 00-15 00-16 00-17 00-18 00-19 00-20 00-21 00-22 00-23 00-24 00-25 00-26 00-27 00-28 01- 1 01- 2 01- 4 01- 5 01-20 01-21 01-22 01-31 01-32 01-33 01-34 01-35 01-36
(3) (3) (3) z
(1) (1)
(1) (3) (3) (3) (2) (2) (3) (3) (3) (1) (2) (2)
11- 1 11- 2 11- 3 11- 4 11- 5 11- 6 11- 7 11- 8 11- 9 11- 10 11- 11 11- 12 11- 14 11- 15 11- 16 11- 17 11- 18 11- 19 11- 20 11- 21 11- 22 11- 24 11- 25 11- 26 11- 27 11- 28 11- 29 11- 30 11- 31 11- 32 11- 33 11- 34 11- 36 11- 37 11- 38 11- 39 11- 40 11- 41 11- 42 11- 43 11- 44 11- 46 11- 47
(2)
z (3) z
(1)
z z
11- 48 11- 49 11- 50 11- 52 11- 53 11- 54 11- 55 11- 56 11- 57 11- 58 11- 60 11- 61 11- 62 11- 64 11- 65 11- 66 11- 68 11- 69 11- 70 11- 71 11- 72 11- 73 11- 74 11- 75 11- 76 11- 77 11- 78 11- 80 11- 81 11- 82 11- 83 11- 84 11- 85 11- 86 11- 87 12- 1 12- 2 12- 3 12- 4 12- 5 12- 6 12- 7 12- 8
(1) (3)
(3)
(1)
(3)
(3) (3) (2) (2) (3) (2) (2)
12121212121212121212121212121212121212121212121212121212121212121212121212121212121212-
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 43 44 45 46 47 48 49 50 51
z z z z
12- 52 12- 53 12- 54 12-101 12-120 12-121 12-140 12-141 12-142 12-143 12-144 12-145 12-146 12-147 12-148 12-149 12-150 12-151 12-152 12-153 12-154 12-155 12-156 12-157 12-158 12-159 12-160 12-161 12-162 12-163 12-164 12-165 12-200 12-201 12-301 12-302 12-303 12-304 12-305 12-306 12-307 12-308 12-309
(3) (1) (3) (3) (3) (2)
(3) (2)
(1)
114 SERIES
00-2-1
(3)
Mark
Pages
Revision number
Mark
Pages
Revision number
Mark
Pages
Revision number
Mark
Pages
Revision number
Mark
Pages
Revision number
12-310 12- 311 12-312 12-313 12-314 12-315 12-316 12-317 12-318 12-319 12-320 12-321 12-322 12-323 13- 1 13- 2 13- 3 13- 4 13- 5 13- 6 13- 7 13- 8 13- 9 13- 10 13- 11 13- 12 13- 13 13- 14 13- 15 13- 16 13- 17 13- 18 13- 19 13- 20 13- 21 13- 22 13- 23 13- 24 13- 25 13- 26 13- 27 13- 28 13- 29 13- 30 13- 31 13- 32 13- 33 13- 34 13- 35 13- 36 13- 37 13- 38 13- 39 13- 40 13- 41 13- 42 13- 43 13- 44 13- 45
13- 46 13- 47 13- 48 13- 49 13- 50 13- 51 13- 52 13- 53 13- 54 13- 55 13- 56 13- 57 13- 58 13- 59 13- 60 13- 61 13- 62 13- 63 13- 64 13- 65 13- 66 13- 67 13- 68 13- 69 13- 70 13- 71 13- 72 13- 73 13- 74 13- 75 13- 76 13- 77 13- 78 13- 79 13- 80 13- 81 13- 82 13- 83 13- 84 13- 85 13- 86 13- 87 13- 88 13- 89 13- 90 13- 91 13- 92 13- 93 13- 94 13- 95 13- 96 13- 97 13- 98 13- 99 13-100 13-101 13-102 13-103 13-104
13-105 13-106 13-107 13-108 13-109 13- 110 13- 111 13- 112 13- 113 13- 114 13- 115 13- 116 13- 117 13- 118 13- 119 13-120 13-121 15- 1 15- 2 15- 3 15- 4 15- 5 15- 6 15- 7 15- 8 15- 9 15- 10 15- 11 15- 12 15- 13 15- 14 15- 15 15- 16 15- 17 15- 18 15- 19 15- 20 15- 21 15- 22 15- 23 15- 24 15- 25 15- 26 15- 27 15- 28 15- 29 15- 30 15- 31 15- 32 15- 33 15- 34 15- 35 15- 36 15- 37 15- 38 15- 39 15- 40 15- 41 15- 42
15151515151515151515151515151515151515151515151515151515-
43 44 45 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
00-2-2
(3)
114 SERIES
SAFETY
SAFETY NOTICE
SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for safe machine operation. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe. Some of these techniques require the use of tools specially designed by Komatsu for the specific purpose. To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation.
GENERAL PRECAUTIONS Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully BEFORE operating the machine. 1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine. 2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. Always wear safety glasses when hitting parts with a hammer. Always wear safety glasses when grinding parts with a grinder, etc.
6. Decide a place in the repair workshop to keep 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 or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working. PREPARATIONS FOR WORK 7. Before adding oil or making any repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving. 8. Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them. 9. When disassembling or assembling, support the machine with blocks, jacks or stands before starting work. 10.Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.
3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, hand shield, cap and other clothes suited for welding work. 4. When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator's compartment. 5. Keep all tools in good condition and learn the correct way to use them.
00-3
SAFETY
SAFETY NOTICE
PRECAUTIONS DURING WORK 11.When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. Before disconnecting or removing components of the oil, water or air circuits, first remove the pressure completely from the circuit. 12.The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned. Wait for the oil and water to cool before carrying out any work on the oil or water circuits. 13.Before starting work, remove the leads from the battery. Always remove the lead from the negative () terminal first. 14.When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage. Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane. 15.When removing covers which are under internal pressure or under pressure from a spring, always leave two bolts in position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove. 16.When removing components, be careful not to break or damage the wiring. Damaged wiring may cause electrical fires. 17.When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips onto the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip, or can even start fires. 18.As a general rule, do not use gasoline to wash parts. In particular, use only the minimum of gasoline when washing electrical parts.
19.Be sure to assemble all parts again in their original places. Replace any damaged parts with new parts. When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is being operated. 20.When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits. Also, check that connecting parts are correctly installed. 21.When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly. 22.When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. 23.When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any measurements. 24.Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates suddenly, so never let anyone stand at either end of the track.
00-4
FOREWORD
GENERAL
FOREWORD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.
STRUCTURE AND FUNCTION This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards. TESTING AND ADJUSTING This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating "Problems" with "Causes" are also included in this section. DISASSEMBLY AND ASSEMBLY This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them. MAINTENANCE STANDARD This section gives the judgment standards for inspection of disassembled parts. The contents of this section may be described in STRUCTURE AND FUNCTION. OTHERS This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. In addition, this section may give the specifications of attachments and options together.
NOTICE
The specifications contained in this shop manual are subject to change at any time and without any advance notice. Use the specifications given in the book with the latest date.
00-5
FOREWORD
HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL

VOLUMES Shop manuals are issued as a guide to carrying out repairs. They are divided as follows: Chassis volume: Issued for every machine model Engine volume: Issued for each engine series Each issued as one Electrical volume: Attachments volume: volume to cover all models
REVISED EDITION MARK When a manual is revised, an edition mark ((1)(2)(3)....) is recorded on the bottom of the pages.
REVISIONS Revised pages are shown in the LIST OF REVISED PAGES next to the CONTENTS page.
These various volumes are designed to avoid duplicating the same information. Therefore, to deal with all repairs for any model , it is necessary that chassis, engine, electrical and attachment volumes be available. DISTRIBUTION AND UPDATING Any additions, amendments or other changes will be sent to KOMATSU distributors. Get the most up-todate information before you start any work.
SYMBOLS So that the shop manual can be of ample practical use, important safety and quality portions are marked with the following symbols.
Symbol
Item Safety
Remarks Special safety precautions are necessary when performing the work. Special technical precautions or other precautions for preserving standards are necessary when performing the work. Weight of parts of systems. Caution necessary when selecting hoisting wire, or when working posture is important, etc. Places that require special attention for the tightening torque during assembly. Places to be coated with adhesives and lubricants, etc. Places where oil, water or fuel must be added, and the capacity. Places where oil or water must be drained, and quantity to be drained.
FILING METHOD 1. See the page number on the bottom of the page. File the pages in correct order. 2. Following examples show how to read the page number. Example 1 (Chassis volume): 10 - 3 Item number (10. Structure and Function) Consecutive page number for each item. Example 2 (Engine volume): 12 - 5 Unit number (1. Engine) Item number (2. Testing and Adjusting) Consecutive page number for each item. 3. Additional pages: Additional pages are indicated by a hyphen (-) and number after the page number. File as in the example. Example: 12-203 10-4 12-203-1 10-4-1 Added pages 12-203-2 10-4-2 12-204 10-5
Caution
Weight
3 2 5 6
Tightening torque
Coat
Oil, water
Drain
00-6
FOREWORD
HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING k Heavy parts (25 kg or more) must be lifted with a hoist, etc. In the DISASSEMBLY AND ASSEMBLY section, every part weighing 25 kg or more is indicated clearly with the symbol 4 If a part cannot be smoothly removed from the machine by hoisting, the following checks should be made: 1) Check for removal of all bolts fastening the part to the relative parts. 2) Check for existence of another part causing interference with the part to be removed. Slinging near the edge of the hook may cause the rope to slip off the hook during hoisting, and a serious accident can result. Hooks have maximum strength at the middle portion.
100%
88%
79%
71%
41%
SAD00479
WIRE ROPES 1) Use adequate ropes depending on the weight of parts to be hoisted, referring to the table below: Wire ropes (Standard "Z" or "S" twist ropes without galvanizing)
Rope diameter mm 10 11.5 12.5 14 16 18 20 22.4 30 40 50 60 Allowable load kN 9.8 13.7 15.7 21.6 27.5 35.3 43.1 54.9 98.1 176.5 274.6 392.2 tons 1.0 1.4 1.6 2.2 2.8 3.6 4.4 5.6 10.0 18.0 28.0 40.0
3) Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound onto the load. 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 winding position on the load, which can result in a dangerous accident.
4) Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with two or more ropes, the force subjected to each rope will increase with the hanging angles. The table below shows the variation of allowable load kN {kg} when hoisting is made with two ropes, each of which is allowed to sling up to 9.8 kN {1000 kg} vertically, at various hanging angles. When two ropes sling a load vertically, up to 19.6 kN {2000 kg} of total weight can be suspended. This weight becomes 9.8 kN {1000 kg} when two ropes make a 120 hanging angle. On the other hand, two ropes are subjected to an excessive force as large as 39.2 kN {4000 kg} if they sling a 19.6 kN {2000 kg} load at a lifting angle of 150.
The allowable load value is estimated to be onesixth or one-seventh of the breaking strength of the rope used.
2) Sling wire ropes from the middle portion of the hook.
00-7
FOREWORD
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

k Before carrying out the following work, release the residual pressure from the hydraulic tank. For details, see TESTING AND ADJUSTING, Releasing residual pressure from hydraulic tank.
Type 1
k Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out when the hose is disconnected. Accordingly, prepare an oil receiving container. Disconnection 1) Release the residual pressure from the hydraulic tank. For details, see TESTING AND ADJUSTING, Releasing residual pressure from hydraulic tank. 2) Hold adapter (1) and push hose joint (2) into mating adapter (3). (See Fig. 1) The adapter can be pushed in about 3.5 mm. Do not hold rubber cap portion (4). 3) After hose joint (2) is pushed into adapter (3), press rubber cap portion (4) against (3) until it clicks. (See Fig. 2) 4) Hold hose adapter (1) or hose (5) and pull it out. (See Fig. 3) Since some hydraulic oil flows out, prepare an oil receiving container. Connection 1) Hold hose adapter (1) or hose (5) and insert it in mating adapter (3), aligning them with each other. (See Fig. 4) Do not hold rubber cap portion (4). 2) After inserting the hose in the mating adapter perfectly, pull it back to check its connecting condition. (See Fig. 5) When the hose is pulled back, the rubber cap portion moves toward the hose about 3.5 mm. This does not indicate abnormality, however.
00-8
FOREWORD
Type 2 1) Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end.
Type 3 1) Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end.
2) Hold in the condition in Step 1), and turn lever (4) to the right (clockwise).
Disassembly
2) Hold in the condition in Step 1), and push until cover (3) contacts contact surface a of the hexagonal portion at the male end.
3) Hold in the condition in Steps 1) and 2), and pull out whole body (2) to disconnect it.
3) Hold in the condition in Steps 1) and 2), and pull out whole body (2) to disconnect it.
Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end to connect it.
Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end to connect it.
Connection
00-9
FOREWORD
COATING MATERIALS
COATING MATERIALS
The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly and assembly are listed below. For coating materials not listed below, use the equivalent of products shown in this list.
Category Komatsu code LT-1A Part No. 790-129-9030 Q'ty 150 g Container Tube Main applications, featuresr Used to prevent rubber gaskets, rubber cushions, and cock plug from coming out. Used in places requiring an immediately effective, strong adhesive. Used for plastics (except polyethylene, polyprophylene, tetrafluoroethlene and vinyl chloride), rubber, metal and non-metal. Features: Resistance to heat and chemicals Used for anti-loosening and sealant purpose for bolts and plugs. Used as adhesive or sealant for metal, glass and plastic. Can
LT-1B
790-129-9050
20 g (2 pcs.)
Polyethylene container
LT-2
09940-00030
50 g Adhesive: 1 kg Hardening agent: 500 g 250 g 75 g
LT-3 Adhesives LT-4 Holtz MH 705 Three bond 1735
790-129-9060 (Set of adhesive and hardening agent) 790-129-9040 790-126-9120
Polyethylene container Tube Polyethylene container
Used as sealant for machined holes. Used as heat-resisting sealant for repairing engine. Quick hardening type adhesive Cure time: within 5 sec. to 3 min. Used mainly for adhesion of metals, rubbers, plastics and woods. Quick hardening type adhesive Quick cure type (max. strength after 30 minutes) Used mainly for adhesion of rubbers, plastics and metals. Resistance to heat, chemicals Used at joint portions subject to high temperatures. Used as adhesive or sealant for gaskets and packing of power train case, etc. Used as sealant for various threads, pipe joints, flanges. Used as sealant for tapered plugs, elbows, nipples of hydraulic piping. Features: Silicon based, resistance to heat, cold Used as sealant for flange surface, tread. Used as sealant for oil pan, final drive case, etc. Features: Silicon based, quick hardening type Used as sealant for flywheel housing, intake manifold, oil an, thermostat housing, etc. Used as heat-resisting sealant for repairing engine. Features: Silicone type, heat resistant, vibration resistant, and impact resistant sealing material Used as sealing material for transfer case
790-129-9140
50 g
Aron-alpha 201 Loctite 648-50 LG-1
790-129-9130
2g
Polyethylene container Polyethylene container Tube
79A-129-9110 790-129-9010
50 cc 200 g
LG-5
790-129-9080
1 kg
Can
LG-6 Gasket sealant LG-7
790-129-9020
200 g
Tube
790-129-9070
1g
Tube
Three bond 1211 Three bond 1207B
790-129-9090
100 g
Tube
419-15-18131
100 g
Tube
00-10
FOREWORD
COATING MATERIALS
Category
Komatsu code LM-G
Part No. 09940-00051
Q'ty 60 g
Container Can
Main applications, featuresr Used as lubricant for sliding portion (to prevent from squeaking). Used to prevent seizure or scuffling of the thread when press fitting or shrink fitting. Used as lubricant for linkage, bearings, etc. General purpose type
Molybdenum disulphide lubricant
LM-P
09940-00040
200 g
Tube
G2-LI
SYG2-400LI SYG2-350LI SYG2-400LI-A SYG2-160LI SYGA-160CNLI SYG2-400CA SYG2-350CA SYG2-400CA-A SYG2-160CA SYGA-160CNCA SYG2-400M SYG2-400M-A SYGA-16CNM SYG2-400T-A SYG2-16CNT SYG0-400T-A (*) SYG0-16CNT (*) SYG2-400B SYGA-16CNB SYG2-400BT (*) SYGA-16CNBT (*)
Various
Various
G2-CA
Various
Various
Used for normal temperature, light load bearing at places in contact with water or steam.
Grease
Molybdenum disulphide grease LM-G (G2-M) Hyper White Grease G2-T G0-T (*) *: For use in cold district Biogrease G2B G2-BT (*) *: For high temperature and large load SUNSTAR PAINT PRIMER 580 SUPER SUNSTAR GLASS PRIMER 580 SUPER SUNSTAR PENGUINE SEAL 580 SUPER "S" or "W" Sika Japan, Sikaflex 256HV SUNSTAR PENGUINE SEAL No. 2505 SEKISUI SILICONE SEALANT
400 g 10 Bellows type 400 g 20 Bellows type 16 kg Can
Used for heavy load portion
400 g 16 kg
Seizure resistance and heat resistance higher than molybdenum diBellows type sulfide grease Can Since this grease is white, it does not stand out against machine body. Bellows type Can Since this grease is decomposed by bacteria in short period, it has less effects on microorganisms, animals, and plants. Used as primer for cab side (Using limit: 4 months) Used as primer for glass side (Using limit: 4 months) Adhesive for cab glass "S" is used for high-temperature season (April - October) and "W" for low-temperature season (November - April) as adhesive for glass. (Using limit: 4 months) Used as adhesive for glass. (Using limit: 6 months) Used to seal joints of glass parts. (Using limit: 4 months) Used to seal front window. (Using limit: 6 months)
400 g 16 kg
20 ml
Glass container Glass container
Primer
20 ml 417-926-3910
320 ml
Adhesive
20Y-54-39850 417-926-3920
310 ml 320 ml
Polyethylene container Polyethylene container Polyethylene container
Caulking material
20Y-54-55130
333 ml
00-11
FOREWORD
STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH) In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in the table below.
Tightening torque Thread diameter of bolt mm 6 8 10 12 14 16 18 20 22 24 27 30 33 36 39 Width across flats mm 10 13 17 19 22 24 27 30 32 36 41 46 50 55 60 Nm 11.8 14.7 27 34 59 74 98 123 153 190 235 285 320 400 455 565 610 765 785 980 1150 1440 1520 1910 1960 2450 2450 3040 2890 3630 Tightening torque Thread diameter of bolt mm 6 8 10 12 Width across flats mm 10 13 14 27 Nm 5.9 9.8 13.7 23.5 34.3 46.1 74.5 90.2 kgm 0.6 1.0 1.4 2.4 3.5 4.7 7.6 9.2 kgm 1.2 1.5 2.8 3.5 6 7.5 10 12.5 15.5 19.5 23.5 29.5 33 41 46.5 58 62.5 78 80 100 118 147 155 195 200 250 250 310 295 370
Sealing surface
TABLE OF TIGHTENING TORQUES FOR FLARED NUTS In the case of flared nuts for which there is no special instruction, tighten to the torque given in the table below.
Thread diameter mm 14 18 22 24 30 33 36 42 Width across flat mm 19 24 27 32 36 41 46 55 Nm 24.5 4.9 49 19.6 78.5 19.6 137.3 29.4 176.5 29.4 196.1 49 245.2 49 294.2 49 Tightening torque
SAD00483
kgm 2.5 0.5 52 82 14 3 18 3 20 5 25 5 30 5
00-12
FOREWORD
TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS In the case of split flange bolts for which there is no special instruction, tighten to the torque given in the table below.
Thread diameter mm 10 12 16
Width across flat mm 14 17 22 Nm 59 74 98 123 235 285
Tightening torque kgm 6 7.5 10 12.5 23.5 29.5
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.
Thread diameter Norminal No. mm 02 03, 04 05, 06 10, 12 14 14 20 24 33 42
Width across flat mm
Tightening torque (Nm {kgm}) Range 35 63 84 132 128 186 363 480 746 1010 {3.5 6.5} {8.5 13.5} {13.0 19.0} {37.0 49.0} {76.0 103} Target 44 {4.5} 103 {10.5} 157 {16.0} 422 {43.0} 883 {90.0}
Varies depending on type of connector.
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS Unless there are special instructions, tighten the O-ring boss plugs to the torque below.
Thread diameter Norminal No. mm 08 10 12 14 16 18 20 24 30 33 36 42 52 08 10 12 14 16 18 20 24 30 33 36 42 52
Width across flat mm 14 17 19 22 24 27 30 32 32 36
Tightening torque (Nm {kgm}) Range 5.88 8.82 9.8 12.74 14.7 19.6 19.6 24.5 24.5 34.3 34.3 44.1 44.1 53.9 58.8 78.4 93.1 122.5 107.8 147.0 127.4 176.4 181.3 240.1 274.4 367.5 {0.6 0.9} {1.0 1.3} {1.5 2.0} {2.0 2.5} {2.5 3.5} {3.5 4.5} {4.5 5.5} {6.0 8.0} {9.5 12.5} {11.0 15.0} {13.0 18.0} {18.5 24.5} {28.0 37.5} Target 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} 124.4 {13.0} 151.9 {15.5} 210.7 {21.5} 323.4 {33.0}
00-13
FOREWORD
TIGHTENING TORQUE FOR 102 ENGINE SERIES 1) BOLT AND NUTS Use these torques for bolts and nuts (unit: mm) of Cummins Engine.
Thread diameter mm 6 8 10 12 10 0 2 24 0 4 43 0 6 77 0 12 Nm Tightening torque 1.02 0 0.20 2.45 0 0.41 4.38 0 0.61 7.85 0 1.22 kgm
2) EYE JOINTS Use these torques for eye joints (unit: mm) of Cummins Engine.
Thread diameter mm 6 8 10 12 14 802 10 0 2 12 0 2 24 0 4 36 0 5 Nm Tightening torque 0.81 0 0.20 1.02 0 0.20 1.22 0 0.20 2.45 0 0.41 3.67 0 0.51 kgm
3) TAPERED SCREWS Use these torques for tapered screws (unit: inch) of Cummins Engine.
Thread diameter inch 1 / 16 1/8 1/4 3/8 1/2 3/4 1 301 802 12 0 2 15 0 2 24 0 4 36 0 5 60 0 9 Nm Tightening torque 0.31 0 0.10 0.81 0 0.20 1.22 0 0.20 1.53 0 0.41 2.45 0 0.41 3.67 0 0.51 6.12 0 0.92 kgm
TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE) Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified. Apply the following torque when the threads are coated (wet) with engine oil.
Tightening torque (Nm {kgm}) Nominal size Width across of hose flats Range 34 - 63 {3.5 - 6.5} 54 - 93 {5.5 - 9.5} 59 - 98 {6.0 - 10.0} 84 - 132 {8.5 - 13.5} 128 - 186 {13.0 - 19.0} 177 - 245 {18.0 - 25.0} 177 - 245 {18.0 - 25.0} 197 - 294 {20.0 - 30.0} 246 - 343 {25.0 - 35.0} Target 44 {4.5} 74 {4.5} 78 {8.0} 103 {10.5} 157 {16.0} 216 {22.0} 216 {22.0} 245 {25.0} 294 {30.0} Taper seal type Face seal type
Nominal thread Thread size size Root diameter - Threads per (mm) inch, Thread series (mm) (Reference) 14 18 22 24 30 33 36 42 9 - 18UNF 16 11 - 16UN 16 13 - 16UN 16 1 - 14UNS 3 1 - 12UNF 16 14.3 17.5 20.7 25.4 30.3
02
19 22 24
03
04 05 06 (10) (12) (14)
27 32 36 41 46 55
00-14
FOREWORD
ELECTRIC WIRE CODE
ELECTRIC WIRE CODE

In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. This wire code table will help you understand WIRING DIAGRAMS. Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.
CLASSIFICATION BY THICKNESS
Copper wire Norminal number Number of strands 11 26 65 84 85 127 217 Dia. of strands (mm2) 0.32 0.32 0.32 0.45 0.80 0.80 0.80 Cross section (mm2) 0.88 2.09 5.23 13.36 42.73 63.84 109.1 Cable O.D. (mm) Current rating (A) Applicable circuit
0.85 2 5 15 40 60 100
2.4 3.1 4.6 7.0 11.4 13.6 17.6
12 20 37 59 135 178 230
Starting, lighting, signal etc. Lighting, signal etc. Charging and signal Starting (Glow plug) Starting Starting Starting
CLASSIFICATION BY COLOR AND CODE

Circuits Priority Classification Primary Code Color Code 2 Color White & Red Code 3 Color White & Black Code 4 Auxiliary WL Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow BR RY YG Yellow & Green YL GY Green & Yellow GB LY Blue & Yellow LB WB White & Black Red & White Rellow & Red Green & White Blue & White BY RB YB GR LR
Charging
Ground
Starting
Lighting
Instrument
Signal
Other
W White WR
B Black
B Black BW
R Red RW
Y Yellow YR
G Green GW
L Blue LW
Color White & Blue Code WG
Black & Red Red & Yellow RG
5 Color White & Green Code 6 Color Red & Blue Yellow & White Green & Blue Red & Green Yellow & Blue Green & Black Blue & Black RL YW GL n n
00-15
FOREWORD
CONVERSION TABLE
CONVERSION TABLE
METHOD OF USING THE CONVERSION TABLE The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the Conversion Table, see the example given below.
EXAMPLE Method of using the Conversion Table to convert from millimeters to inches 1. Convert 55 mm into inches. (1) Locate the number 50 in the vertical column at the left side, take this as A, 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 perpendicular line down from B. (3) Take the point where the two lines cross as C. This point C gives the value when converting from millimeters to inches. Therefore, 55 mm = 2.165 inches. 2. Convert 550 mm into inches. (1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the left) to convert it to 55 mm. (2) Carry out the same procedure as above to convert 55 mm to 2.165 inches. (3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches. B Millimeters to inches
1 mm = 0.03937 in
0 0 10 20 30 40 A 50 60 70 80 90 0 0.394 0.787 1.181 1.575 1.969 2.362 2.756 3.150 3.543
1 0.039 0.433 0.827 1.220 1.614 2.008 2.402 2.795 3.189 3.583
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 2.874 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 C 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
8 0.315 0.709 1.102 1.496 1.890 2.283 2.677 3.071 3.465 3.858
9 0.354 0.748 1.142 1.536 1.929 2.323 2.717 3.110 3.504 3.898
00-16
FOREWORD
CONVERSION TABLE
Millimeters to Inches
1 mm = 0.03937 in
0 0 10 20 30 40 50 60 70 80 90 0 0.394 0.787 1.181 1.575 1.969 2.362 2.756 3.150 3.543
1 0.039 0.433 0.827 1.220 1.614 2.008 2.402 2.795 3.189 3.583
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 2.874 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
8 0.315 0.709 1.102 1.496 1.890 2.283 2.677 3.071 3.465 3.858
9 0.354 0.748 1.142 1.536 1.929 2.323 2.717 3.110 3.504 3.898
Kilogram to Pound
1 kg = 2.2046 lb
0 0 10 20 30 40 50 60 70 80 90 0 22.05 44.09 66.14 88.18 110.23 132.28 154.32 176.37 198.42
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
8 17.64 39.68 61.73 83.78 105.82 127.87 149.91 171.96 194.01 216.05
9 19.84 41.89 63.93 85.98 108.03 130.07 152.12 174.17 196.21 218.26
00-17
FOREWORD
CONVERSION TABLE
Liter to U.S. Gallon 0 0 10 20 30 40 50 60 70 80 90 0 2.642 5.283 7.925 10.567 13.209 15.850 18.492 21.134 23.775 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 7 1.849 4.491 7.133 9.774 12.416 15.058 17.700 20.341 22.983 25.625
1l = 0.2642 U.S. Gal
8 2.113 4.755 7.397 10.039 12.680 15.322 17.964 20.605 23.247 25.889
9 2.378 5.019 7.661 10.303 12.944 15.586 18.228 20.870 23.511 26.153
Liter to U.K. Gallon 0 0 10 20 30 40 50 60 70 80 90 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 7.969 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 7 1.540 3.740 5.939 8.139 10.339 12.528 14.738 16.938 19.137 21.337
1l = 0.21997 U.K. Gal
8 1.760 3.950 6.159 8.359 10.559 12.758 14.958 17.158 19.357 21.557
9 1.980 4.179 6.379 8.579 10.778 12.978 15.178 17.378 19.577 21.777
00-18
FOREWORD
CONVERSION TABLE
kgm to ft. lb
1 kgm = 7.233 ft. lb
0 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 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 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
8 57.9 130.2 202.5 274.9 347.2 419.5 491.8 564.2 636.5 708.8 781.2 853.5 925.8 998.2 1070.5 1142.8 1215.1 1287.5 1359.8 1432.1
9 65.1 137.4 209.8 282.1 354.4 426.8 499.1 571.4 643.7 716.1 788.4 860.7 933.1 1005.4 1077.7 1150.0 1222.4 1294.7 1367.0 1439.4
00-19
FOREWORD
CONVERSION TABLE
kg/cm2 to lb/in2
1kg/cm2 = 14.2233 lb/in2
0 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 0 142.2 284.5 426.7 568.9 711.2 853.4 995.6 1138 1280 1422 1565 1707 1849 1991 2134 2276 2418 2560 2702 2845 2987 3129 3271 3414
1 14.2 156.5 298.7 440.9 583.2 725.4 867.6 1010 1152 1294 1437 1579 1721 1863 2005 2148 2290 2432 2574 2717 2859 3001 3143 3286 3428
2 28.4 170.7 312.9 455.1 597.4 739.6 881.8 1024 1166 1309 1451 1593 1735 1877 2020 2162 2304 2446 2589 2731 2873 3015 3158 3300 3442
3 42.7 184.9 327.1 469.4 611.6 753.8 896.1 1038 1181 1323 1465 1607 1749 1892 2034 2176 2318 2460 2603 2745 2887 3030 3172 3314 3456
4 56.9 199.1 341.4 483.6 625.8 768.1 910.3 1053 1195 1337 1479 1621 1764 1906 2048 2190 2333 2475 2617 2759 2901 3044 3186 3328 3470
5 71.1 213.4 355.6 497.8 640.1 782.3 924.5 1067 1209 1351 1493 1636 1778 1920 2062 2205 2347 2489 2631 2773 2916 3058 3200 3343 3485
6 85.3 227.6 369.8 512.0 654.3 796.5 938.7 1081 1223 1365 1508 1650 1792 1934 2077 2219 2361 2503 2646 2788 2930 3072 3214 3357 3499
7 99.6 241.8 384.0 526.3 668.5 810.7 953.0 1095 1237 1380 1522 1664 1806 1949 2091 2233 2375 2518 2660 2802 2944 3086 3229 3371 3513
8 113.8 256.0 398.3 540.5 682.7 825.0 967.2 1109 1252 1394 1536 1678 1821 1963 2105 2247 2389 2532 2674 2816 2958 3101 3243 3385 3527
9 128.0 270.2 412.5 554.7 696.9 839.2 981.4 1124 1266 1408 1550 1693 1835 1977 2119 2262 2404 2546 2688 2830 2973 3115 3257 3399 3542
00-20
FOREWORD
CONVERSION TABLE
Temperature Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface column of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left. If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right.
1C = 33.8F
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 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 0 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 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175
F 117.8 179.6 181.4 183.2 185.0 186.8 188.6 190.4 192.2 194.0 195.8 197.6 199.4 201.2 203.0 204.8 206.6 208.4 210.2 212.0 221.0 230.0 239.0 248.0 257.0 266.0 275.0 284.0 293.0 302.0 311.0 320.0 329.0 338.0 347.0
00-21
FOREWORD
UNITS
UNITS
In this manual, the measuring units are indicated with Internatinal System of units (SI). As for reference, conventionally used Gravitational System of units are indicated in parentheses { Example: N {kg} Nm {kgm} MPa {kg/cm2} kPa {mmH2O} kPa {mmHg} kW/rpm {HP/rpm} g/kWh {g/HPh}
}.
00-22
FOREWORD
CAPSCREW MARKINGS AND TORQUE VALUSES
CAPSCREW MARKINGS AND TORQUE VALUES When replacing capscrews, always use a capscrew of the same measurement and strength as the
capscrew being replaced. Using the wrong capscrews can result in engine damage. Metric capscrews and nuts are identified by the grade number stamped on the head of the capscrew or on the surface of the nuts. U.S. Customary capscrews are identified by radial lines stamped on the head of the capscrew. The following examples indicate how capscrews are identified: Metric - M8 - 1.25 X 25 M8 Major Thread Diameter in Millimeters NOTES: 1. 2. 3. 4. Always use the torque values listed in the following tables when specific torque values are not available. Do not use the torque values in place of those specified in other sections of this manual. The torque values in the table are based on the use of lubricated threads. When the ft-lb value is less than 10, give consideration to converting the ft-lb value to in-lb to obtain a better torque with an in-lb torque wrench. Example: 6 ft-lb equals 72 in-lb. 1.25 Distance Between Threads in Millimeters 25 Length in Millimeters U.S. Customary (5/16 X1 8 X 1-1/2) M8 Major Thread Diameter in Inches 1.25 Number Threads per Inch 25 Length in Inches
114 SERIES
00-23
FOREWORD
CAPSCREW MARKINGS AND TORQUE VALUES - METRIC

Commercial Steel Class 8.8 Capscrew Head Markings 10.9 12.9
Body Size Diam. Cast Iron
Torque Aluminum Cast Iron
Torque Aluminum Cast Iron
Torque Aluminum
mm kgm Nm ft-lb kgm Nm ft-lb kgm Nm ft-lb kgm Nm ft-lb kgm Nm ft-lb kgm Nm ft-lb
6 7 8 10 12 0.92 1.4 2.5 4.6 8.2 9 14 25 45 80 125 180 230 5 9 18 33 60 90 0.71 1.1 1.8 3.1 5.6 9.2 7 11 18 30 55 90 140 180 4 7 14 25 1.2 1.8 3.4 6.1 12 18 33 60 105 165 240 320 9 14 25 45 75 122 0.71 1.1 1.8 3.1 5.6 9.2 7 11 18 30 55 90 140 180 4 7 14 25 1.4 2.3 4.1 7.1 14 23 40 70 125 195 290 400 9 18 29 50 95 145 0.71 1.1 1.8 3.1 5.6 9.2 7 11 18 30 55 90 140 180 4 7 14 25 40 65 100 135
40 10.7 65 16.8 100 24.5 135 32.6
40 12.7 65 19.9 100 29.6 135 40.8
14 12.7 16 18.4 18 23.5
130 14.3 170 18.4
175 14.3 240 18.4
210 14.2 290 18.4
00-24
1
114 SERIES
FOREWORD
CAPSCREW MARKINGS AND TORQUE VALUES - U.S. CUSTOMARY

SAE grade number Capscrew Head Markings These are all SAE Grade 5 (3) line.
Capscrew Torque - Grade 5 Capscrew Capscrew Torque - Grade 5 Capscrew Capscrew Body Size Cast Iron mm
1/4 - 20 - 28 5/16 - 18 - 24 3/8 - 16 - 24 7/16 - 14 - 20 1/2 - 13 - 20 9/16 - 12 - 18 5/8 - 11 - 18 3/4 - 10 - 16 7/8 - 9 - 14 1-8 - 14
Aluminum kgm
0.82 0.92 1.6 1.9 2.5 3.6 4.6 5.6 7.6 8.2
Cast Iron kgm

1.5 1.8 3.1 3.4 5.6 6.1 9.2 9.7 13.3 15.3 19.4 21.4 26 29.6 46.9 52.5 76 84.1
Aluminum kgm
0.82 0.92 1.6 1.9 2.5 3.6 4.6 5.6 7.6 8.2
kgm
0.92 1.2 2.0 2.3 4.1 4.1 6.1 6.6 9.7 10.2 13.8 15.3 18.4 21.4 33.1 37.2 50 54 73.4 81.6
Nm
9 12 20 23 40 40 60 65 95 100 135 150 180 210 325 365 490 530 720 800
ft-lb
7 9 15 17 30 30 45 50 70 75
Nm
8 9 16 19 25 35 45 55 75 80 110 115 150 160 255 285 380 420 570 650
ft-lb
6 7 12 14 20 25 35 40 55 60 80 85 110 120 190 210 280 310
Nm
15 18 30 33 55 60 90 95 130 150 190 210 255 290 460 515 745 825 1100 1200
ft-lb
11 13 22 24 40 45 65 70 95 110
Nm
8 9 16 19 25 35 45 55 75 80 110 115 150 160 255 285 380 420 570 650
ft-lb
6 7 12 14 20 25 35 40 55 60 80 85 110 120 190 210 280 310 420 480
100 11.2 110 11.7 135 15.3 155 16.3 240 26 270 29.1 360 38.7 390 42.8 530 58.1 590 66.3
140 11.2 155 11.7 190 15.3 215 16.3 340 26 380 29.1 550 38.7 610 42.8 820 58.1 890 66.5
420 112.2 480 122.4
114 SERIES
00-25
1
FOREWORD
PIPE PLUG TORQUE VALUES
PIPE PLUG TORQUE VALUES

Size Thread in
1/16 1/8 1/4 3/8 1/2 3/4 1 1 - 1/4 1 - 1/2
Torque In Aluminum Components kgm

0.51 1.5 2.0 2.5 3.7 4.6 6.1 7.6 8.7
Torque In Cast Iron or Steel Components kgm

1.5 2.0 2.5 3.7 5.6 7.6 9.7 11.7 13.8
Actual Thread O.D. in

0.32 0.41 0.54 0.68 0.85 1.05 1.32 1.66 1.90
Nm
5 15 20 25 35 45 60 75 85
ft-lb
45 in-lb 10 15 20 25 35 45 55 65
Nm
15 20 25 35 55 75 95 115 135
ft-lb
10 15 20 25 40 55 70 85 100
00-26
114 SERIES
FOREWORD
SYMBOLS
SYMBOLS
The following symbols have been used in this manual to help communicate the intent of the instructions. When one of the symbols appears, it conveys the meaning defined below: WARNING - Serious personal injury or extensive property damage can result if the warning instructions are not followed. CAUTION - Minor personal injury can result or a part, an assembly, or the engine can be damaged if the caution instructions are not followed. Indicates a REMOVAL or DISASSEMBLY step.
Indicates an INSTALLATION or ASSEMBLY step.
INSPECTION is required.
CLEAN the part or assembly.
PERFORM a mechanical or time MEASUREMENT.
LUBRICATE the part or assembly.
Indicates that a WRENCH or TOOL SIZE will be given.
TIGHTEN to a specific torque.
PERFORM an electrical MEASUREMENT.
Refer to another location in this manual or another publication for additional information.
The component weights 23 kg (50 lb) or more. To avoid personal injury, use a hoist or get assistance to lift the component.
114 SERIES
00-27
FOREWORD
SYMBOLS
ILLUSTRATIONS
The illustrations used in the "Repair Sections" of this manual are intended to give an example of a problem, and to show what to look for and where the problem can be found. Some of the illustrations are 'generic" and will not look exactly like the engine or parts used in your application. Some illustrations contain symbols to indicate and action required, and an acceptable or not acceptable condition.
The illustrations are intended to show repair or replacement procedures with the engine "in-chassis". The illustration can differ from your application, but the procedure given will be the same.
00-28
114 SERIES
01 GENERAL
Applicable machine .....................................................................................................................................01- 2 Specification ................................................................................................................................................01- 4 Overall drawing............................................................................................................................................01-20 Weight table.................................................................................................................................................01-31 Engine performance curve ..........................................................................................................................01-32
114 SERIES
01-1
1
GENERAL
APPLICABLE MACHINE
APPLICABLE MACHINE
Engine
Engine serial No. PC300-7 WA380-5
Applicable machine Hydraulic excavator Wheel loader Motor grader Motor grader Crawler carrier
SAA6D114E-2
GD655-3A,3C GD675-3A,3C CD110R-2
01-2
(3)
114 SERIES
GENERAL
APPLICABLE MACHINE
114 SERIES
01-3
GENERAL
SPECIFICATION
SPECIFICATION
Engine Applicable model No. of cylinders - Bore x Stroke Total piston displacement Firing order Overall length Dimensions Overall width Overall height (excluding exhaust pipe) Overall height (including exhaust pipe) Flywheel horsepower kW/rpm {HP/rpm} Max. torque Performance Nm/rpm {kgm/ rpm} High idling speed Low idling speed Min. fuel consumption ratio Dry weight Fuel injection pump Governor Lubricating oil amount (refil capacity) Coolant amount Alternator Starting motor Battery Turbocharger Air compressor Others 40 (35) 9.8 (engine only) 24V, 35A 24V, 7.5Kw 12V, 108Ah x 2 HOLSET HX40W with air cooled aftercooler rpm 90025 rpm g/kWh {g/HPh} kg 213 {159} 860 204 {152} 870 BOSCH P3000 type centrifugal, all speed type 37 (32) 9.8 (engine only) 24V, 60A 24V, 7.5Kw 12V, 150Ah x 2 HOLSET HX40W with air cooled aftercooler 24 (19) 9.8 (engine only) 24V, 60A or 24V, 90A 24V, 7.5Kw or 24V, 11Kw 12V, 150Ah x 2 HOLSET HX40W with air cooled aftercooler 850+50 0 82550 mm 180/1,900 {242/1,900} (Net) 1,080/1,400 {110/1,400} (Net) 2,16050 140/2,000 {190/2,000} (Net) 883/1,400 {90/1,400} (Net) 2,23050 147/1,900 {197/1,900} (Gross) 940/1,400 {96/1,400} (Gross) 2,22550 mm mm mm 1,615 825 1,300 mm {cc} PC300-7 SAA6D114E-2 WA380-5 6 - 114 x 135 8.27 {8.268} 1-5-3-6-2-4 1,166 906 1,632 1,130 747 1,418 GD655-3A,3C
213 {159} 750
01-4
(3)
114 SERIES
GENERAL
SAA6D114E-2 GD675-3A,3C CD110R-2 6 - 114 x 135 8.27 {8.268} 1-5-3-6-2-4 1,130 747 1,418 1,405 987 1,392
154/1,900 {206/1,900} (Gross) 989/1,400 {101/1,400} (Gross) 2,22550 82550
180/1,900 {242/1,900} (Net) 1,080/1,400 {110/1,400} (Net) 2,16050 90025
215 {160} 750
213 {160} 850 BOSCH P3000 type centrifugal, all speed type
24 (19) 9.8 (engine only) 24V, 60A or 24V, 90A 24V, 7.5Kw or 24V, 11Kw 12V, 150Ah x 2 HOLSET HX40W with air cooled aftercooler
24 (19) 9.8 (engine only) 24V, 35A 24V, 7.5Kw 12V, 108Ah x 2 HOLSET HX40W with air cooled aftercooler
114 SERIES
01-5
(3)
GENERAL
OVERALL DRAWING
OVERALL DRAWING
SAA6D114E-2 LEFT SIDE DRAWING
5 The diagram shows the equipment for the PC300-7. 5 The shape may differ according to the machine model.
a. Crankshaft center b. Flywheel housing rear surface
01-20
(2)
114 SERIES
GENERAL
OVERALL DRAWING
SAA6D114E-2 FRONT DRAWING

5 The diagram shows the equipment for the PC300-7. 5 The shape may differ according to the machine model.
a. Crankshaft center b. Cylinder liner center
114 SERIES
01-21
(2)
GENERAL
OVERALL DRAWING
DIMENSION TABLE
5 These dimensions are reference values for use when installing to a test bench. (Unit:mm) Dimensions for each part A 1,357 1,166 1,130 1,130 1,357 B 1,300 1,632 1,418 1,418 1,392 C 856 1,235 1,093 1,093 992 D 444 397 325 325 400 E 480 445 424 424 619 F 345 461 423 423 368 G 258 48
Engine
Machine model PC300-7 WA380-5
SAA6D114E-2
GD655-3A,3C GD675-3A,3C CD110R-2
01-22
(3) 1
114 SERIES
GENERAL
WEIGHT TABLE
WEIGHT TABLE
(Unit: kg) No. 1 Item Turbocharger Cylinder head assembly Main component _ Cylinder head, valve rocker arm, valve spring Cylinder block, bearing cap _ _ Flywheel, ring gear _ Crankshaft,Crankshaft gear Camshaft, Camshaft gear, thrust plate PIston, piston ring, piston pin, connecting rod _ BOSCH type _ _ _ _ SAA6D114E -2
3 4 5 6 7 8
Cylinder block assembly Front cover Oil pan Flywheel assembly Flywheel housing Crankshaft assembly Camshaft assembly
Piston, connecting 10 rod assembly
11 Oil pump 12 Fuel injection pump 13 Water pump 14 Alternator 15 Starting motor 16 Aftercooler assembly
114 SERIES
01-31
GENERAL
ENGINE PERFORMANCE CURVE
Engine
Engine Serial No.
Machine model PC300-7, CD110R-2
Page 01-33 01-34 01-35 01-36
SAA6D114E-2
WA380-5 GD655-3A,3C GD675-3A,3C
01-32
(3)
114 SERIES
GENERAL
SAA6D114E-2 (PC300-7, CD110R-2)

Flywheel horsepower: 180kW {242HP}/1,950rpm (Net) Maximum torque : 1,080Nm {110kgm}/1,400rpm (Net)
114 SERIES
01-33
(3)
GENERAL
SAA6D114E-2 (WA380-5)
Flywheel horsepower : 151.5kW {203HP}/2,000rpm (Gross) Maximum torque : 945Nm {96.4kgm}/1,400rpm (Gross)
01-34
1
114 SERIES
GENERAL
SAA6D114E-2 (GD655-3A,3C)
Flywheel horsepower Maximum torque : 147kW {197HP}/1,900rpm (Gross) : 940Nm {96kgm}/1,400rpm (Gross)
114 SERIES
01-35
(2)
GENERAL
SAA6D114E-2 (GD675-3A,3C)
Flywheel horsepower Maximum torque : 154kW {206HP}/1,900rpm (Gross) : 989Nm {101kgm}/1,400rpm (Gross)
01-36
(2)
114 SERIES
STRUCTURE AND FUNCTION
11 STRUCTURE AND FUNCTION

AIR INTAKE DEVICE ............................................11-2 EXHAUST MANIFOLD .........................................11-5 AIR CLEANER ......................................................11-6 TURBOCHARGER ...............................................11-7 AFTERCOOLER ...................................................11-12 CYLINDER HEAD .................................................11-14 CYLINDER BLOCK ..............................................11-18 CYLINDER LINER ................................................11-22 MAIN CIRCULATION PART .................................11-24 CRANK SHAFT ....................................................11-28 PISTON PISTON RING PISTON PIN ..............11-30 CONNECTING ROD .............................................11-32 VIBRATION DAMPER ..........................................11-34 TIMING GEAR PORTION .....................................11-36 FRONT GEAR COVER ........................................11-37 CAMSHAFT TIMING PIN .....................................11-38 TIMING GEAR ......................................................11-39 CAM SHAFT .........................................................11-40 VALVE MECHANISM ............................................11-42 VALVE, VALVE GUIDE .........................................11-46 ROCKER-ARM SHAFT PUSH ROD TAPPET ................................................................11-48 OIL PAN ................................................................11-50 FLYWHEEL, FLYWHEEL HOUSING ................... 11-52 LUBRICATION SYSTEM DIAGRAM .................... 11-56 OIL PUMP ............................................................ 11-57 OIL FILTER, OIL COOLER .................................. 11-60 REGULATOR VALVE, SAFETY VALVE ............... 11-61 FUEL SYSTEM DIAGRAM .................................. 11-62 FUEL INJECTION PUMP .................................... 11-64 TIMING LOCK PIN OF FUEL INJECTION PUMP ............................................... 11-68 FUEL FILTER ....................................................... 11-69 FUEL INJECTION NOZZLE ................................. 11-70 FUEL CUT SOLENOID ........................................ 11-72 COOLING SYSTEM DIAGRAM ........................... 11-73 WATER PUMP DRIVE ......................................... 11-74 WATER PUMP ..................................................... 11-76 (WITH ONE-PIECE BEARING, SHAFT, ONE-PIECE WATER SEAL) ................................ 11-76 THERMOSTAT ..................................................... 11-77 FAN DRIVE .......................................................... 11-80 ALTERNATOR ..................................................... 11-82 STARTING MOTOR ............................................. 11-85 STARTING AID .................................................... 11-87
114 SERIES
11-1
(2)
AIR INTAKE DEVICE
AIR INTAKE DEVICE

SAA6D114E-2
5 The shape may differ according to the machine it is mounted on.
' Air connector ' Electrical intake air heater ' Cylinder head (forms one unit with intake manifold) 4' Muffler 5' Exhaust pipe 6' Exhaust pipe (turbocharger - muffler) 7' Turbocharger 8' Exhaust manifold
1 2 3
A: Air supply inlet B: Front face of cylinder block
11-2
114 SERIES
AIR INTAKE DEVICE
114 SERIES
11-3
AIR INTAKE DEVICE
OUTLINE OF INTAKE AND EXHAUST SYSTEM

This engine is equipped with a turbocharger and aircooled aftercooler. The air passes through the air cleaner and is sucked into the engine. This air must be clean to ensure the service life of the engine. If dirt or dust is sucked in, it will immediately damage the cylinders. Always use a high-quality air cleaner and clean or replace the air cleaner element according to the procedures specified in the Operation and Maintenance Manual. The air sucked into an engine with turbocharger and air-cooled aftercooler is sucked in from the air cleaner through the compressor side of the turbocharger. It is sent from the turbocharger, passes through the cooling fins of the air-cooled aftercooler, and is then sent from the intake manifold to the cylinder, where it is used for combustion. The exhaust gas flows to the exhaust side of the turbocharger, and the energy of the exhaust gas is used to drive the turbine wheel. The turbine wheel and the shaft drive the compressor wheel and send large amounts of air to the cylinder for combustion. If the amount of air sent by the turbocharger is increased, it is possible to increase the amount of fuel injected, and this increases the engine output. If it is also cooled, the density of the air is increased, and more oxygen is supplied, so the amount of fuel injected can be further increased to increase the output of the engine. There are also engines with a turbocharger that use an exhaust turbocharger to limit the maximum boost pressure and drive the turbocharger. The exhaust actuation is controlled by an actuator that detects the compressor pressure and balances it with the preset force of a spring. The exhaust valve is in the turbine suction passage. When the valve opens, part of the exhaust gas deviates from the turbine wheel, so the shaft and boost can be controlled.
Note: The turbocharger is a high-performance product, so do not touch or adjust it unless necessary. The exhaust bracket forms one unit with the turbocharger. If the exhaust components are touched unnecessarily, the pressure in the intake and exhaust manifolds will become part of adjustment, and the cylinder pressure and heat load will increase, so the durability will drop. The fuel consumption will increase and the exhaust system will no longer conform to the exhaust regulations. Even if the turbocharger boost is raised, the engine output will not increase. The terminal, compressor wheel, and shaft are supported by the bearing housing with two roller bearings. The passage inside the bearing housing is directly filtered, and the engine oil is pressurized against the shaft bearing and thrust bearing. The oil is used for lubricating and cooling the rotating components to allow them to move smoothly. The oil is drained from the bearing housing through the oil drain line, and drops into the oil pan. If there is resistance or damage in the drain line, the turbocharger bearing housing will be pressurized, and this will cause leakage of oil from the seal. Note: An ample supply of good quality filtered oil is necessary to ensure the service life of the turbocharger. Always use high-quality oil and change the oil and oil filters according to the specified maintenance procedures.
11-4
114 SERIES
EXHAUST MANIFOLD
EXHAUST MANIFOLD
Unit:mm
No. Check item Flatness of exhaust manifold 1 mounting surface Flatness of turbocharger 2 charger mounting flange surface 0.13 Criteria Remedy
0.20 Replace
114 SERIES
11-5
AIR CLEANER
AIR CLEANER
FRG TYPE (CYCLOPACK TYPE)
FRG TYPE (RADIAL SEAL TYPE) 5 The shape may differ according to the machine it is mounted on.
1. Outlet 2. Inlet 3. Body

Engine
4. Outer element 5. Inner element 6. Latch

Machine model PC300-7 WA380-5 GD655-3A,3C GD675-3A,3C CD110R-2 Type
7. Vacuator valve
Actuator valve
No. of elements
SAA6D114E-2
FRG (Radial seal type)
Automatic discharge
Inner element x 1, outer element x 1
Features (FRG type) Since this air cleaner is sealed in the radial direction, the reliability of the seal is high. To remove the cleaner element of the current air cleaner, the wing nut must be removed. The cleaner element of this air cleaner can be removed, however, by just undoing latch (6). The inlet is installed off the center of the air cleaner so that air will swirl and separate dust with centrifugal force as shown in Fig. 1. Structure Air containing dust is sucked through inlet (2) tangentially and the dust is separated by the centrifugal effect of the guide vanes. Furthermore, more than 99.9% of the dust is removed by outer element (4) and clean air is sucked through inner element (5) and outlet (1) into the engine. The dust and water separated by the guide vanes flow along the inside wall of body (3) and enter evacuator valve (7), and then they are discharged automatically.
11-6
(3)
114 SERIES
TURBOCHARGER
TURBOCHARGER
SAA6D114E-2
' Retainer 2' Blower housing 3' O-ring 4' Piston ring 5' Slinger 6' Locknut 7' Blower impeller 8' Retainer 9' Baffle oil 10' Thrust bearing 11' Thrust collar 12' Center housing 13' Journal bearing 14' Retainer
1 114 SERIES
' 16' Turbine impeller 17' Piston ring 18' Shroud (heat shield) 19' Gasket 20' Turbine housing 21' Plate 22' Actuator
15 Adapter A. Intake inlet port B. Air supply outlet port C. Exhaust inlet port D. Exhaust outlet port E. Oil inlet port F. Oil outlet port
Specifications Type: Holsett HX40W Applicable exhaust temperature: Max. 700C (inlet port) Direction of rotation: Clockwise (as seen from blower)
11-7
TURBOCHARGER
OUTLINE OF WASTE GATE VALVE

This maintains a suitable supercharging pressure (set supercharging pressure) in order to prevent any excessive load on the engine by suppressing any supercharging above the necessary level from the compressor. In order to do this, waste gate valve (1) is installed in the exhaust circuit before the turbine. When supercharged pressure (A) near the compressor outlet port becomes high, if it exceeds the set pressure of the actuator (swing valve control (2)), waste gate valve (swing valve) (1) opens. Point c where engine speed a and supercharging pressure b intersect is the point where the waste gate valves start to open.
Pressure (A) near the outlet port of the compressor passes through (B) and actuates actuator (2). Waste gate valve (1) opens, and part of the exhaust gas bypasses the turbine, so the output of the turbine drops and the set supercharging pressure is maintained.
11-8
114 SERIES
TURBOCHARGER
LUBRICATION OF TURBOCHARGER
The shape may differ according to the machine it is mounted on.
The oil filtered and cooled by the turbocharger is sent from the filter head through supply pipe (1). The oil then passes through return pipe (2) that is interconnected at the bottom of the turbocharger housing, passes through the fitting in the engine block, and returns to the oil pan.
114 SERIES
11-9
TURBOCHARGER
TURBO CHARGER
11-10
114 SERIES
TURBOCHARGER
Unit:mm
No. Check item Play in radial direction of 1 2 3 rotor Play in axial direction of rotor ightening torque of turbine housing bolt Outside diameter of wheel 4 shaft Curvature of wheel shaft 5 Inside diameter of back plate Inside diameter of center 6 housing Criteria Remedy
' ' '
0.33~0.50 0.03~0.09 14Nm {1.4kgm}
Repair or replace
Tighten
10.97~10.98 Repair limit: 0.008 (total movement of indicator) 19.305~19.330 Replace
' '
15.875~15.885 19.305~19.330
114 SERIES
11-11
AFTERCOOLER
AFTERCOOLER
AIR-COOLED TYPE
SAA6D114E-2 5 The shape may differ according to the machine it is mounted on.
1. 2. 3. 4.
Side support Tube Fin Tank
A: From turbocharger B: To intake manifold
11-12
1
114 SERIES
20-242
D155AX-5
CYLINDER HEAD
CYLINDER HEAD
1. 2. 3. 4. 5. 6. 7.
Cylinder head Head cover Breather Oil filler cap Head bolt Nozzle holder Gasket
8. Valve insert (intake side) 9. Valve insert (exhaust side)
11-14
114 SERIES
CYLINDER HEAD
Specifications Head cover Float mount type Cylinder head Direct injection type Monocoque type 2 valve (1 cylinder) Injection nozzle mount: Dry type (no sleeve)
Valve seat Intake side: Insert press fitted Exhaust side: Insert press fitted
114 SERIES
11-15
CYLINDER HEAD
CYLINDER HEAD
11-16
114 SERIES
CYLINDER HEAD
Unit:mm
No. Check item Vertical Distortion of cylinder head 1 mounting surface direction Lateral direction Step 1st step: All Tightening torque of cylinder head mounting bolts 2 (coat bolt seat and thread with molybdenum disulphide (LM-P)) 4th step (long m ounting bolts only) C heck again 5th step Tightening torque of nozzle 3 holder Tightening torque of head 4 cover mounting bolt 24Nm {2.4kgm} Tighten 24Nm {2.4kgm} 145Nm {14.8kgm} Tighten 90 2nd step: Check again 3rd step (long mounting bolts only) 70Nm {7.1kgm} 145Nm {14.8kgm} Criteria Remedy
0.20
Repair by grinding or replace
0.76 Tightening torque 70Nm {7.1kgm}
Tighten in order shown in diagram on left
114 SERIES
11-17
CYLINDER BLOCK
CYLINDER BLOCK
1 2 3 4
' Main bearing cap ' Main bearing cap bolt ' Cylinder block ' Cam bushing (journal No. 1)
a. Center of crankshaft b. Rear face of cylinder block c. Piston cooling nozzle d. Thrust surface (top surface only, No. 4 journal)
11-18
114 SERIES
CYLINDER BLOCK
Specifications Cylinder block Crankshaft: 7 bearings Cam shaft: 7 bearings Cylinder liner Wet type Machining of inside surface: Honing
Piston cooling With nozzle piston cooling Cylinder liner ring O-ring (x1)
114 SERIES
11-19
CYLINDER BLOCK
CYLINDER BLOCK
11-20
114 SERIES
CYLINDER BLOCK
Unit:mm
No. Check item Distortion of cylinder head 1 mounting surface Inside diam eter of m ain bearing installation 2 (Tighten m ounting bolt to 176 Nm (17.9 kgm )) Inside diameter of main 3a bearing (Tighten bolt to 176 Nm (17.9 kgm)) 3b Thickness of main bearing Inside diameter of cam 4 bushing mounting hole Inside diameter of cam 5 bushing Step Tightening torque of main bearing cap mounting bolt 6 (coat bolt thread and seat with engine oil) 3rd step Tightening torque of oil pan 7 mounting bolt Tightening torque of crank8 shaft pulley pan mounting bolt 200Nm {20.4kgm} Tighten 60 5 Tighten 1st step 2nd step 50Nm {5.1kgm} 95Nm {9.7kgm} 3.340~3.345 Correct or Max. 64.01 replace cylinder block 60.058~60.112 Replace bushing 98.079~98.125 Replace main bearing Standard size 104.982~105.018 Vertical direction Lateral direction Criteria 0.075 0.075 Remedy Correct by grinding
Correct or replace cylinder block
Tightening torque
24Nm {2.45kgm}
114 SERIES
11-21
CYLINDER LINER
CYLINDER LINER
Unit:mm
No. Check item Inside diameter Roundness of inside 1 diameter Cylindricity of inside diameter Criteria 114.0000~114.040 0.01 Remedy Correct to oversize, install cylinder liner, or 0.01 replace cylinder block
11-22
114 SERIES
20-242
D155AX-5
MAIN CIRCULATION PART

SAA6D114E-2 5 5 The shape may differ according to the machine it is mounted on. The numbers in ( ) are used for reference when showing the same part in other places or when explaining about the same part seen from a different angle.
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
Crankshaft pulley Crankshaft Pin Crankshaft gear (No. of teeth: 42) Main bearing Connecting rod bearing Connecting rod Cylinder block Cylinder liner Piston Connecting rod bushing
12. 13. 14. 15. 16. 17. 18. 19. 20.
Piston pin Top ring Second ring Oil ring Connecting rod cap bolt Connecting rod cap Connecting rod cap nut Main bearing Thrust bearing (top surface only, No. 4 journal) 21. Main cap bolt
a. Ring carrier b. Toroidal
11-24
114 SERIES
Specifications Crankshaft Closed die forging, induction hardening Piston Toroidal combustion chamber for direct injection type Aluminum piston
Piston ring
Top ring Second ring Oil ring
Barrel face keystone inner cut, hard chrome plating
Rectangular inner cut, barrel face keystone inner cut, parkerizing
With coil expander, M-shape steel ring, hard chrome plating
114 SERIES
11-25
CRANKSHAFT AND MAIN BEARING

The crankshaft is a balance type forged steel product. On the 6-cylinder engine, there are seven main bearings. The bottom bearing shells are all the same. The top bearing shells are all the same except for the journal at the rear. A top bearing shell with flange is installed to the journal next to the rear journal. The flange controls the end of thrust of the crankshaft. There are three holes in the top bearing. The center hole takes the oil from the main oil rifle. The neighboring hole is aligned with the hole going to the camshaft journal, and acts as an orifice for the oil flowing to the journal. The final hole supplies oil for cooling the piston. This hole is not completely aligned with the cooling nozzle. The hole is offset to prevent it from being subjected to the high load of the bearing portion.
PISTON CONNECTING ROD

The special features of the piston are the strong swirl combustion bowl cast aluminium body and 3ring group. The engine with turbocharger and aftercooler is equipped with a trapezoidal ni resist insert for the top piston ring. When replacing the pis-ton, always check the part number and confirm that the structure is correct. The piston rings have a 3-ring structure. The top ring on the engine with turbocharger and aftercooler is a trapezoidal shape and is actuated by the ni resist insert cast into the piston.
11-26
114 SERIES
A free floating hole piston pin is used to connect the piston and connecting rod. Lubrication of the pin and journal is performed by a spray from the piston cooling.
The piston end of the connecting rod is cut at an angle to make the bearing surface larger. The end of the connecting rod is fitted with a bronze bushing.
The engine with turbocharger and air-cooled aftercooler uses a steel-back 3-layer bearing to enable it to withstand a large load.
To prevent any mistake in the two types of bearing when carrying out repairs, only the steel-back 3layer bearing can be used for service.
114 SERIES
11-27
CRANK SHAFT
CRANK SHAFT
11-28
114 SERIES
PISTON PISTON RING PISTON PIN
PISTON PISTON RING PISTON PIN
11-30
114 SERIES
CONNECTING ROD
CONNECTING ROD
11-32
114 SERIES
VIBRATION DAMPER
VIBRATION DAMPER
Unit:mm
No. 1 Check item Lost rubber material Inside/ outside misalign2 ment of damper (A) Face runout of damper (B) Tightening torque of vibra3 tion damper 200Nm {20.4 kgm} Tighten Criteria 3.18 1.59 Replace Remedy
11-34
114 SERIES
20-242
D155AX-5
TIMING GEAR PORTION
TIMING GEAR PORTION

Without front PTO (helical gear) SAA6D114E-2
1. 2. 3. 4. 5. 6.
Oil pump drive gear Idler gear Crankshaft gear Cam gear Fuel injection pump drive gear Timing pin
(No. of teeth: 24) (No. of teeth: 23) (No. of teeth: 42) (No. of teeth: 84) (No. of teeth: 84)
11-36
114 SERIES
FRONT GEAR COVER
FRONT GEAR COVER

SAA6D114E-2
1. 2. 3. 4. 5. 6. 7. 8. 9.
Front gear cover Front gear housing Gasket Front seal cover Front seal Accessory cover plate Ring seal Timing pin housing Timing pin
Specifications 2-layer sheet metal wall structure
114 SERIES
11-37
CAMSHAFT TIMING PIN
CAMSHAFT TIMING PIN

5 SAA6D114E-2 1. Timing housing 2. Timing pin @ The shape may differ according to the machine it is mounted on.
Align the timing pin of the housing with the #1 piston TOP , and assemble. (Without positioning) When removing the housing, align with the #1 piston TOP .
FRONT OIL SEAL

The front crankshaft seal is installed to the front gear cover. A double lip Teflon seal is used. Keep the crankshaft seal surface clean and free of oil during assembly.
11-38
114 SERIES
TIMING GEAR
TIMING GEAR
Unit:mm
No. Check item A B _ Backlash of each gear C D Criteria Backlash of oil pump gear Backlash of camshaft gear Backlash of oil pump gear Backlash of fuel injection pump gear 0.08~0.33 0.075~0.325 0.08~0.33 0.075~0.0325 Replace Remedy
114 SERIES
11-39
CAM SHAFT
CAM SHAFT
11-40
114 SERIES
CAM SHAFT
Unit:mm
No. Check item Criteria Remedy Replace thrust plate Correct or replace
End play Outside diameter of cam-
0.10~0.36
2 3
shaft bearing journal Curvature of camshaft Intake
59.987~60.013 0.15 (total movement of indicator) Min. 51.774 Min. 51.596 Min. 41.31
Height of camshaft
Exhaust Fuel feed pump Valve position Intake open
Replace
Crank angle Check for Before top dead center After bottom dead center Before bottom dead center After top dead center 10 34 45 10 wear, curvature of push rod, camshaft, valve, correct or replace
Valve timing
Intake close Exhaust open Exhaust close
Outside diameter of cam6 shaft gear mounting face Outside diameter of cam7 shaft thrust bearing journal Thickness of camshaft thrust 8 plate Inside diameter of camshaft 9 gear bore ightening torque of camshaft 10 thrust plate mounting bolt
41.562~41.580
45.550~45.750 Replace 9.34~9.58
41.480~41.505
24Nm {2.45kgm}
Tighten
114 SERIES
11-41
VALVE MECHANISM
VALVE MECHANISM
SAA6D114E-2
1. 2. 3. 4. 5. 6. 7. 8.
Cam bushing (No. 1 journal) Cam gear (No. of teeth: 84) Thrust plate Camshaft Exhaust valve Intake valve Rocker arm bracket Valve seat (intake, exhaust)
9. 10. 11. 12. 13. 14. 15. 16.
Valve spring Valve cotter Spring seal Adjustment screw Locknut Rocker arm Push rod Tappet
11-42
114 SERIES
VALVE MECHANISM
CAMSHAFT, TAPPET, PUSH ROD

The camshaft is driven by a gear from the crankshaft. The front journal uses a replaceable bushing to make it possible to transmit the side load from the accessory drive. The other journals move inside the cast iron bore of the cylinder block, but if the maintenance bushing is installed, these bores can be corrected at a workshop.
The camshaft has a special rope to drive the fuel feed pump and a rope actuating the intake and exhaust valves. The valve rope is in contact with the mushroom-shaped valve tappet that actuates the push rod. The actuation arm of the fuel feed pump is installed directly above the special rope of the camshaft.
The tappet is mushroom shaped. The protruding surface is in contact with the camshaft rope, so the tappet rotates while raising the push rod.
The ball-shaped end of the push rod fits in the ball socket of the tappet. The other end of the push rod forms a socket, and the ball-shaped end of the rocker lever adjustment thread fits in it.
11-44
114 SERIES
20-242
D155AX-5
VALVE, VALVE GUIDE
VALVE, VALVE GUIDE
11-46
114 SERIES
ROCKER-ARM SHAFT PUSH ROD TAPPET
ROCKER-ARM SHAFT PUSH ROD TAPPET
11-48
114 SERIES
OIL PAN
OIL PAN
FRONT SUMP TYPE
SAA6D114E-2 (PC300-7) 5 The shape may differ according to the machine it is mounted on.
1. 2. 3. 4. 5.
Oil level gauge Underplate Oil pan Oil level sensor Drain valve
11-50
1
114 SERIES
20-242
D155AX-5
FLYWHEEL, FLYWHEEL HOUSING

SAA6D114E-2 5The shape may differ according to the machine it is mounted on.
1. Flywheel housing 2. Starting motor 3. Ring gear (No. of teeth: 148) (PC300-7, CD110R-2) (No. of teeth: 127) (WA380-5) 4. Flywheel
5. 6. 7. 8.
Rear seal Rear seal housing Seal ring Speed sensor (PC300-7, WA380-5, CD110R-2)
11-52
(3)
114 SERIES
Specifications Rear seal Dry type: Single lip with dust seal Wet type: Double lip
114 SERIES
11-53
FLYWHEELFLYWHEEL HOUSING
11-54
114 SERIES
Unit:mm
No. 1 2 Check item Face runout of flywheel housing Radial runout of flywheel housing Tightening torque of flywheel housing mounting bolt For clutch 4 Face runout of flywheel For torque converter Criteria 0.20 Reassemble, 0.20 correct Remedy
77Nm {7.85 kgm} 0.013/24.5 Diameter at measured point x 0.0005 0.13
Tighten
Reassemble, correct
Radial runout of flywheel
Tightening torque of flywheel 6 mounting bolt (Coat bolt thread portion with engine oil.) 137Nm {14.0 kgm} Tighten
Inside diameter of flywheel housing
409.58 (WA380-5) 511.18 (PC300-7, CD110R-2)
114 SERIES
11-55
(3)
LUBRICATION SYSTEM DIAGRAM
LUBRICATION SYSTEM DIAGRAM

1. 2. 3. 4.
Oil strainer Oil pump Oil cooler Safety valve (oil cooler bypass valve) 5. Regulator valve 6. Oil filter
7. Safety valve (oil filter bypass valve) 8. Crankshaft 9. Camshaft 10. Piston 11. Intake/exhaust valve 12. Rocker arm
13. 14. 15. 16. 17.
Timing gear Fuel injection pump Turbocharger Piston cooling Low-pressure oil pressure switch 18. High-pressure oil pressure switch
11-56
114 SERIES
OIL PUMP
OIL PUMP
1. 2. 3. 4. 5. 6. 7. 8. 9.
Drive gear (No. of teeth: 24) Bushing Drive shaft Housing Idler shaft Idler gear (No. of teeth: 23) Back plate Inner rotor (drive rotor) Outer rotor (planetary rotor)
Specifications Type: Trochoid pump Rotating speed: Engine speed x 1.75
114 SERIES
11-57
OIL PUMP
OIL PUMP
Unit:mm
No. Check item Clearance of rotor in axial 1 direction Clearance between outer rotor 2 and body Clearance between outer rotor 3 and inner rotor Step Tightening torque of oil pump 4 mounting bolt 1st step 2nd step Criteria Remedy
0.025~0.127 Replace oil pump
0.127~0.381
0.025~0.1778 Tightening torque 5Nm {0.5 kgm} 24Nm {2.4 kgm} Tighten
11-58
114 SERIES
20-242
D155AX-5
OIL FILTER, OIL COOLER
OIL FILTER, OIL COOLER

SAA6D114E-2 5
1. 2. 3. 4. 5. 6. 7.
Oil filter cartridge Regulator valve Adapter Oil filter head Oil cooler core assembly Oil pump Safety valve
Specifications Oil cooler No. of element stages: 12
11-60
114 SERIES
REGULATOR VALVE, SAFETY VALVE
REGULATOR VALVE, SAFETY VALVE

SAA6D114E-2
Regulator valve 1. Plug 2. Spring 3. Plunger valve Safety valve 4. Oil filter 5. Safety valve 6. Oil cooler A. To oil cooler B. From oil pump C. To oil pan D. From oil filter E. From oil filter F. To main oil gallery
Specifications Regulator valve Cracking pressure: 517 KPa{5.3kg/cm2} Safety valve Cracking pressure: 345 KPa{3.5kg/cm2}
114 SERIES
11-61
FUEL SYSTEM DIAGRAM
FUEL SYSTEM DIAGRAM

1. 2. 3. 4.
Fuel tank Priming pump Feed pump Fuel filter
5. Fuel injection pump 6. Fuel injection nozzle 7. Overflow valve
11-62
114 SERIES
20-242
D155AX-5
FUEL INJECTION PUMP
FUEL INJECTION PUMP

1. 2. 3. 4. 5. 6. 7.
Fuel injection pump (main body) Fuel injection pipe (No. 1) Fuel injection pipe (No. 2) Fuel injection pipe (No. 3) Fuel injection pipe (No. 4) Fuel injection pipe (No. 5) Fuel injection pipe (No. 6)
8. 9. 10. 11. 12. 13. 14.
Boost compensator Governor Boost compensator tube Fuel filter Feed pump Timing lock Overflow valve
11-64
114 SERIES
FUEL INJECTION PUMP
A. Fuel inlet B. To fuel filter C. To fuel filter D. From fuel filter E. To fuel injection nozzle F. To fuel tank (overflow) G. From oil pump (oil supply)
Specifications Fuel injection pump Type: Bosch P3000 Lubrication method: Forced lubrication using engine oil Governor Type: Bosch RSV Centrifugal all-speed type
114 SERIES
11-65
20-242
D155AX-5
TIMING LOCK PIN OF FUEL INJECTION PUMP
TIMING LOCK PIN OF FUEL INJECTION PUMP

5 1. Timing lock pin locked 5 When checking the injection timing of the No 1 cylinder, install lock pin (1-1) in the reverse direction from the operating condition. The shape may differ according to the machine it is mounted on.
2. Timing lock pin released 5 The condition of lock pin (1-2) shows the condition when operating. 5 (2) shows the damper proof hold.
11-68
114 SERIES
FUEL FILTER
FUEL FILTER
1. Bracket (filter head) 2. Connector 3. Cartridge A. Fuel inlet port B. Fuel outlet port
Specification Fuel filter Filtering area: 0.4 m2
114 SERIES
11-69
FUEL INJECTION NOZZLE

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Gasket Retaining cap Nozzle body Needle valve Disc Injector Injector seal Shim (for adjusting cracking pressure) Spring Push rod
A. Fuel inlet port (from injection pump) B. Fuel outlet port (inside fuel chamber) C. Fuel return port (to fuel tank) Specifications Type: Bosch multi-hole type, cylindrical type Injection pressure (adjusting cracking pressure) 30MPa {306kg/cm2} Adjusting cracking pressure: Shim adjustment
11-70
114 SERIES
Unit:mm
No. Check item Spray angle Standard 1 Nozzle cracking pressure (injection pressure) 29.4~30.4 MPa {300~310 kg/cm2} Standard size Free length of nozzle spring 2 Installed load of nozzle spring Replace Installed length Standard load Load limit Repair limit Repair limit Adjust or replace Criteria Remedy Replace nozzle
114 SERIES
11-71
FUEL CUT SOLENOID
FUEL CUT SOLENOID
1. Connector 2. Solenoid case 3. Rod end When the engine is started, electricity flows through the solenoid, so the solenoid plunger is actuated to extend the return spring (built into the solenoid) and hold it pulled to the engine RUN position. When the engine is stopped, the starting switch is turned to the STOP position and the flow of electricity to the solenoid stops. The solenoid is no longer energized, so the force of the return spring moves the stop lever of the fuel injection pump to the engine STOP position (no injection). The solenoid plunger is also pulled back at the same time, and the engine stops. When the engine is running, the fuel injection amount is controlled by the fuel control lever.
Specifications Type B contact Rated voltage Actuating current Suction force Stroke
: Synchrostart : Electricity flows in ordinary operations type. : DC24V : At suction 29.3A : At hold: 0.58A : 89N {9.1 kg} : 25.4 mm
11-72
1
114 SERIES
COOLING SYSTEM DIAGRAM
COOLING SYSTEM DIAGRAM

SAA6D114E-3
1. Radiator 2. Corrosion resistor (installation depends on machine model) 3. Thermostat 4. Water temperature gauge 5. Cylinder head 6. Piston
7. Cylinder block 8. Oil cooler 9. Water pump A. Oil inlet, outlet
114 SERIES
11-73
WATER PUMP DRIVE
WATER PUMP DRIVE

5 5 The shape may differ according to the machine it is mounted on. The illustration shows the PC300-7.
1. 2. 3. 4. 5. 6.
Polyvinyl V-belt Crankshaft pulley Auto tensioner Water pump Alternator Idler pulley
A. To radiator B. From radiator a, b, c, d, e: Outside diameter of pulley
11-74
114 SERIES
WATER PUMP DRIVE
OUTSIDE DIAMETER OF PULLEY

(Unit:mm)
Outside diameter of pulley Engine Machine model a (Water pump) PC300-7 CD110R-2 SAA6D114E-2 WA380-5 GD655-3A,3C GD675-3A,3C 116 116 116 116 b (Alternator) 80 80 80 80 c (Tensioner) 73 73 73 73 d (Idler) 73 73 180 180 e (Crankshaft) 198 198 198 198
114 SERIES
11-75
(3)
WATER PUMP
WATER PUMP
(WITH ONE-PIECE BEARING, SHAFT, ONE-PIECE WATER SEAL)
5 Depending on the machine model, the actual component may be different from the diagram.
1. 2. 3. 4. 5.
Impeller Water seal Pump body Pulley Drive shaft
Water pump Type: Centrifugal, driven by poly vinyl V-belt
A. Water inlet port B. Water outlet port (to engine) C. Breather (drain hole)
11-76
114 SERIES
THERMOSTAT
THERMOSTAT
1. 2. 3. 4. 5.
Piston Spring Case Bypass spring Bypass valve
114 SERIES
11-77
THERMOSTAT
THERMOSTAT
Unit:mm
No. Check item Cracking temperature: 80C 1 Thermostat Fully open temperature: 95C Fully open lift amount: 11 Criteria Fully open: Must open when soaked in hot water of 95 - 77C for 4 - 5 min (soak in hot water of 95C for 4 - 5 min) Replace Remedy
11-78
114 SERIES
20-242
D155AX-5
FAN DRIVE
FAN DRIVE
1. 2. 3. 4. 5. 6.
Crankshaft pulley Poly v-belt Auto tensioner Fan Fan hub Fan bracket
A.
Direction of air flow a, b, c: Outside diameter of pulley pickup port
11-80
114 SERIES
FAN DRIVE
OUTSIDE DIAMETER OF PULLEY

(Unit:mm)
Outside diameter of pulley Engine Machine model a (Fan) PC300-7 CD110R-2 SAA6D114E-2 228 228 b (Tensioner) 73 73 c (Crankshaft) 170 170
Note: WA380-5, GD655-3A,3C, GD675-3A,3C has no fan drive.
114 SERIES
11-81
(3)
ALTERNATOR
ALTERNATOR
Alternator with built-in regulator (35A)
1. 2. 3. 4. 5.
Alternator (main body) Alternator pulley Terminal E Terminal B Terminal R
6. Internal connection diagram 3A. Field coil 3B. Initial magnetize resestor 3C. Regulator
Pulley Engine Machine model Type Specification No. of steps PC300-7 CD110R-2 Nikko Denki, open type Polyethylene V-belt, 8 grooves Outside diameter 80 Weight (kg)
SAA6D114E-2
24V, 35A
8.0
11-82
(3)
114 SERIES
ALTERNATOR
1. 2. 3. 4. 5.
Alternator (main body) Alternator pulley Terminal E Terminal B Terminal R
Pulley Engine Machine model Type Specification No. of steps WA380-5 SAA6D114E-2 GD655-3A,3C GD675-3A,3C Outside diameter Weight (kg)
Nikko Denki, open type
24V, 60A
Polyethylene V-belt, 8 grooves
80
11.0
114 SERIES
11-83
1 (2)
ALTERNATOR
1. 2. 3. 4. 5.
Alternator (main body) Alternator pulley Terminal R Terminal B Terminal E
Pulley Engine Machine model Type Specification No. of steps GD655-3A,3C GD675-3A,3C Nikko Denki, open type Polyethylene V-belt, 8 grooves Outside diameter 80 Weight (kg)
SAA6D114E-2
24V, 90A
19.0
11-84
1 ( 2)
114 SERIES
STARTING MOTOR
STARTING MOTOR
7.5KW
1. 2. 3. 4. 5. 6.
Pinion gear Magnetic switch Starting motor (yoke) Terminal B Terminal C Air hole for water proof test
7. External connecting diagram 7A. Safety relay 7B. Starting motor 8. Connector type A type: 2P connector (male) B type: 2P sealed type connector (male) S to starter switch terminal C R to Alternator terminal R
Type Specification No. of pinion teeth Weight (kg) Connector type
Engine
Machine model PC300-7 WA380-5 GD655-3A,3C GD675-3A,3C CD110R-2
SAA6D114E-2
Nikko Denki, sealed type
24V, 7.5kW
12
15.5
114 SERIES
11-85
(3)
11KW
1. 2. 3. 4. 5. 6. 7.
Pinion gear Starting motor (Assembly) Magnetic switch Terminal B Terminal C Safety relay External connecting diagram
7A. Safety relay 7B. Starting motor A type: 2P connector (male) B type: 2P sealed type connector (male) S to starter switch terminal C R to Alternator terminal R E to ground
Engine
Machine model GD655-3A,3C GD675-3A,3C
Type
Specification
No. of pinion teeth 12
Weight (kg)
Connector type B
SAA6D114E-2
Nikko Denki, sealed type
24V, 11kW
18.0
11-86
(2)
114 SERIES
STARTING AID
STARTING AID
ELECTRICAL HEATER (ELECTRICAL INTAKE AIR HEATER)
1. Heater coil 2. Housing 3. Internal connection diagram Electrical heater (electrical intake air heater) Rated current: 100 A/DC 22 V
114 SERIES
11-87
20-242
D155AX-5
TESTING AND ADJUSTING
12 TESTING AND ADJUSTING

Special tool list ...................................................................................................................................... 12-4 Special tools for intake and exhaust system ................................................................................... 12-4 Special tools for cylinder head system ............................................................................................ 12-5 Special tools for engine ................................................................................................................... 12-9 Special tools for fuel system .......................................................................................................... 12-13 Special tools for accessory component system ............................................................................ 12-14 Special tools for electrical component ........................................................................................... 12-15 Special tools for engine performance test ..................................................................................... 12-16 INTAKE AND EXHAUST SYSTEM Troubleshooting defective actuation of intake and exhaust system ..................................................... 12-18 Measuring play of turbocharger rotor in axial and radial direction ....................................................... 12-23 Testing turbocharger westgate valve ................................................................................................... 12-24 Testing turbocharger westgate capsule ............................................................................................... 12-25 Testing actuation of turbocharger westgate ......................................................................................... 12-25 Replacing turbocharger westgate actuator boost capsule ................................................................... 12-26 Adjusting turbocharger westgate actuator ........................................................................................... 12-28 Measuring exhaust resistance ............................................................................................................. 12-29 Replacing tubocharger ........................................................................................................................ 12-29 ENGINE Troubleshooting defective actuation of engine ..................................................................................... 12-30 Valve mechanism and cylinder head ............................................................................................. 12-30 Testing air system and fuel system ............................................................................................... 12-30 Testing valve clearance ................................................................................................................. 12-31 Testing compression ...................................................................................................................... 12-31 Piston ring sealing performance .................................................................................................... 12-31 Valve sealing performance ............................................................................................................ 12-32 Head gasket sealing performance ................................................................................................. 12-32 Valve seal wear ............................................................................................................................. 12-33 Protruding portion of fuel injection nozzle ..................................................................................... 12-34
114 SERIES
12-1
.ront gear housing and gear train ................................................................................................. 12-35 Rocker lever, valve stem, push rod, tappet, and camshaft ............................................................ 12-36 Piston and connecting rod ............................................................................................................. 12-37 Crankshaft and main bearing ........................................................................................................ 12-39 Cylinder block ................................................................................................................................ 12-40 .lywheel housing and flywheel ...................................................................................................... 12-41 Adjusting valve clearance .................................................................................................................... 12-42 Adjusting 6-cylinder engine ........................................................................................................... 12-43 LUBRICATING SYSTEM Troubleshooting defective actuation of lubricating system ................................................................... 12-45 High pressure ................................................................................................................................ 12-45 Regulator valve .............................................................................................................................. 12-45 Low pressure ................................................................................................................................. 12-46 Oil level .......................................................................................................................................... 12-46 Oil filter .......................................................................................................................................... 12-46 Oil pressure gauge ........................................................................................................................ 12-47 Oil pan suction tube ....................................................................................................................... 12-47 Bearing and oil pump ..................................................................................................................... 12-47 Dilution of oil .................................................................................................................................. 12-47 Cooling water in oil ........................................................................................................................ 12-48 .uel in oil ....................................................................................................................................... 12-49 .UEL .uel injection pump calibration data .................................................................................................... 12-52 Running in standard ........................................................................................................................... 12-101 Performance test criteria .................................................................................................................... 12-120 Testing fuel feed pump ....................................................................................................................... 12-140 Disassembly and assembly of fuel feed pump ............................................................................ 12-141 Adjusting fuel cut-off solenoid ............................................................................................................ 12-143 Direction of fuel cut-off solenoid .................................................................................................. 12-143 Adjusting fuel cut-off solenoid ...................................................................................................... 12-144 Installation of mechanically operated solenoid, cylinder block .................................................... 12-145 Testing for air inside the fuel system .................................................................................................. 12-146 Testing water separator, fuel filter ...................................................................................................... 12-148 Testing high-pressure fuel piping ....................................................................................................... 12-149 Testing fuel injection nozzle ............................................................................................................... 12-150
12-2
114 SERIES
Testing fuel drain piping ..................................................................................................................... 12-152 Bleeding air from fuel system ............................................................................................................ 12-152 Bleeding air from low-pressure circuit and fuel filter .................................................................... 12-153 Bleeding air from fuel injection pump .......................................................................................... 12-153 Bleeding air from high-pressure circuit ........................................................................................ 12-154 Adjusting timing of fuel injection pump .............................................................................................. 12-155 COOLING SYSTEM Troubleshooting defective operation of cooling system ..................................................................... 12-158 Radiator cap ................................................................................................................................ 12-160 Water pump ................................................................................................................................. 12-161 Radiator, fan, and radiator shutter ............................................................................................... 12-162 Thermostat .................................................................................................................................. 12-163 Water temperature gauge, excessive fuel, overload ................................................................... 12-165 STANDARD VALUE TABLE .OR TESTING, ADJUSTING, AND TROUBLESHOOTING .................... 12-200 TROUBLESHOOTING O. ENGINE (S MODE) ...................................................................................... 12-301
114 SERIES
12-3
SPECIAL TOOL LIST
SPECIAL TOOL LIST

SPECIAL TOOLS .OR INTAKE AND EXHAUST SYSTEM
We recommend that you use the tools listed below. The tool to use is specified in the respective procedure. Tool No. Depth gauge This is used to measure the movement of the turbo795-790-1800 charger in the axial direction. Explanation of tool Sketch of tool
Pressure gauge This is used to measure the intake manifold pressure 795-790-1470 and the exhaust return pressure.
Pressure test kit This is used to measure the exhaust pressure. 795-790-1700
12-4
114 SERIES
SPECIAL TOOL LIST
SPECIAL TOOLS .OR CYLINDER HEAD SYSTEM

The tools shown below are used when carrying out inspection of the cylinder head. .or details of the method of using the tools, see the applicable operation procedure. Tool No. Explanation of tool Valve spring compression tool This is used to compress the valve spring when removST-488 ing the valve cotter. Sketch of tool
Cylinder head holding tool This is used to hold the cylinder head when rotating it ST-583 during repair or assembly.
Valve seat grinder This is used to grind the valve seat inside the cylinder ST-685 head. Choose the suitable grindstone from the tool list of valve guide arbors (Part No. 3823187) and various valve seat grindstones. Valve seat grinder This is used to grind the exhaust valve seat angle to ST-6835-13 15. (Diameter 47.6 mm)
Magnetic particle flaw detector This is used to inspect the inside diameter of the injecST-1166 tor at the cylinder head combustion surface and cracks in the valve seat. The kit includes the powder spraying valve (Part No. ST-1166-7) to spray the metal powder (Part No. ST-1166-8). Valve vacuum tester A vacuum cup (Part No. ST-1257-6) is installed when ST-1257 the tester is used. This is used to carry out a vacuum test on the cylinder head to check if the valve seat surface is normal.
114 SERIES
12-5
SPECIAL TOOL LIST
Tool No.
Explanation of tool Valve seat puller tool This is used when removing the exhaust valve seat from the cylinder head. It is used together with a slide hammer (Part No. 3376617).
Sketch of tool
ST-1276-1
Valve spring tester This is used to measure the tension of the cylinder head 3375182 valve spring.
Light-load power-drive puller This is used when removing the expansion plug from 3375784 the cylinder head.
Valve chamfering machine This is used to grind the cylinder head valve and to cor3376256 rect the valve stem surface.
Valve seat groove cutting kit This is used together with the cutter (Part No. 3376407) 3376405 of the valve seat puller tool (Part No. ST-1276 and Part No. 337-7396) in order to remove the valve seat from the cylinder head. Slide hammer assembly This is used together with the valve seat puller tool (Part 3376617 No. ST-1276 and Part No. 337-7396) in order to remove the valve seat from the cylinder head.
Expansion plug driver This is used when installing the 3/4 inch expansion plug 3376815 to the determined depth.
12-6
114 SERIES
SPECIAL TOOL LIST
Tool No.
Explanation of tool Valve seat puller tool This is used when removing the intake valve seat from the cylinder head. It is used together with a slide hammer (Part No. 3376617).
Sketch of tool
3377396
Valve guide reamer This is used to enlarge the valve guide hole to a suitable 3822490 inside diameter after assembly.
Injector hole brush This is used to remove all the carbon from the injector 3822510 hole.
Valve seat grindstones 3823179 3823180 3823182 Used to grind intake valve seat angle to 5 (diameter: 57.2 mm) Used to grind intake valve seat angle to 30 (diameter: 53.9 mm) Used to grind intake valve seat angle to 45 (diameter: 47.6 mm) 3823184 3823185 Used to grind exhaust valve seat angle to 60 (diameter: 44.4 mm) Used to grind intake valve seat angle to 60 (diameter: 50.8 mm) Valve seat grinding arbor This is used together with Part No. ST-685, the valve 3823187 seat grinder, and various grindstones to maintain a suitable alignment during the grinding operation.
3823272 3823269 3823270 3823271
Valve guide drive circuit This is used to install the intake valve guide. This is used to install the exhaust valve guide. This is used to remove the intake and exhaust valve guides.
114 SERIES
12-7
SPECIAL TOOL LIST
Tool No. Gauge block
Explanation of tool This is used to measure the sinking of the valve and the
Sketch of tool
3823495
protrusion of the injector from the top surface of the cylinder head.
Expansion plug driver This is used to install the 13/16 inch expansion plug to 3823522 the specified depth.
Expansion plug driver This is used to install the 2-1/4 inch expansion plug to 3823524 the specified depth.
Bolt length gauge This is used to check the free length of the cylinder 3823921 head mounting bolt.
12-8
114 SERIES
SPECIAL TOOL LIST
SPECIAL TOOLS .OR ENGINE

We recommend the use of the tools shown below when carrying out inspection of the engine. .or details of the method of using the tools, see the applicable operation procedure. Tool No. Explanation of tool Connecting rod inspection holder This is used to measure the length, sag, and alignment ST-561 of the inside diameter of the connecting rod. It is used together with the connecting rod inspection mandrel kit (Part No. 3823286). Dowel pin puller This is used to remove the dowel pin. ST-1134 Sketch of tool
Expansion plug sealant This is used to prevent leakage when installing tapered 3375068 thread plugs or cup plugs to the engine.
Dial bore gauge kit This is used to measure the inside diameter from 78.5 3375072 to 203.2 mm.
Crack detection kit This is used to detect cracks. 3375432
Light-load power-drive puller This is used when removing the expansion plug. 3375784
114 SERIES
12-9
SPECIAL TOOL LIST
Tool No. Nylon sling
Explanation of tool This is used when removing or installing the crankshaft,
Sketch of tool
3375957
flywheel, or other heavy components.
Handle for expansion plug drive This is used for all large expansion plugs with a diame3376795 ter of 9.5 mm or more.
Expansion plug driver This is used to install the 25.4 mm expansion plug to the 3376816 specified depth. It is used together with the handle of the expansion plug driver (Part No. 3376795).
Expansion plug driver This is used to install the 9.5 mm expansion plug to the 3822372 specified depth.
Metric thread insertion kit This is used to repair the damaged internal metric 3822709 thread.
Piston ring expansion This is used to install the piston ring to the piston with3823137 out damaging or deforming the ring.
Connecting rod mandrel kit This is used to measure the length, sag, and alignment 3823286 of the inside diameter of the connecting rod. It is used together with the connecting rod inspection inspection holder (Part No. ST-561).
12-10
114 SERIES
SPECIAL TOOL LIST
Tool No.
Explanation of tool Camshaft bushing removal/installation tool This is used to remove or install the camshaft bushing.
Sketch of tool
3823509
Expansion plug driver This is used to install the 57.2 mm expansion plug to the 3823524 specified depth.
Connecting rod pin bushing removal/installation tool 3823690 This is used to remove or install the service bushing at the end of the connecting rod pin.
Bolt length gauge This is used to measure the free length of the bolt. 3823291
114 SERIES
12-11
SPECIAL TOOL LIST
Tool No.
Explanation of tool Wear gauge for piston ring groove (keystone) This is used to measure the wear of the keystone angle of the middle piston ring groove.
Sketch of tool
3823965
Wear gauge for piston ring groove (keystone) This is used to measure the wear of the keystone angle 3823966 of the top piston ring groove.
12-12
114 SERIES
SPECIAL TOOL LIST
SPECIAL TOOLS .OR .UEL SYSTEM

We recommend the use of the tools shown below when carrying out inspection of the fuel system. .or details of the method of using the tools, see the applicable operation procedure. Tool No. Brush This is used to clean the fuel injection nozzle bore. 795-799-1140 Explanation of tool Sketch of tool
Injector nozzle tester This is used to test the cracking pressure, leakage, 3376946 chattering, and spray pattern.
Nozzle cleaning kit This is used to clean the injection nozzle. 3376947
114 SERIES
12-13
SPECIAL TOOL LIST
SPECIAL TOOLS .OR ACCESSORY COMPONENT SYSTEM

We recommend the use of the tools shown below when carrying out inspection of the accessory component system. .or details of the method of using the tools, see the applicable operation procedure. Tool No. Oil filter wrench This is used to remove or install the oil filter. 3375049 Explanation of tool Sketch of tool
Valve spring tester This is used to measure the spring force at the specified 3375182 height.
Tube cutter This is used to open the full-flow oil filter when inspect3376579 ing the filter element.
Oil cooler pressure test kit This is used to test the pressure of the oil cooler ele3823876 ment.
Dial gauge and sleeve assembly This is used together with the magnet base (Part No. 3376050 3377399) to measure the clearance from the fan hub.
Magnet base dial gauge holder This is used together with the dial gauge and sleeve 3377399 assembly (Part No. 3376050).
Standard puller This is used to replace the drive gear. ST-647
12-14
114 SERIES
SPECIAL TOOL LIST
SPECIAL TOOLS .OR ELECTRICAL COMPONENT

We recommend the use of the tools shown below when carrying out inspection of the electrical component. .or details of the method of using the tools, see the applicable operation procedure. Tool No. Multimeter This is used to measure the voltage in the circuit and Commercially available resistance. Explanation of tool Sketch of tool
114 SERIES
12-15
SPECIAL TOOL LIST
SPECIAL TOOLS .OR ENGINE PER.ORMANCE TEST

We recommend that you use the tools listed below. The tool to use is specified in the respective procedure. Tool No. Vacuum gauge This is used to test the resistance of the fuel filter during 795-790-1500 the engine performance test. Use Part No. ST-434-2 (hose adapter) and Part No. ST-434-12 (vacuum gauge) to carry out the test. Pressure gauge This is used to measure the pressure in the engine 795-790-1470 intake manifold. Explanation of tool Sketch of tool
Wrench This is used to remove or tighten the spin-on lubricating 795-799-1320 oil filter or fuel filter.
Blow-by tool This is used to test the blow-by in the engine crankcase. 795-790-1900
Manometer This is used together with the blow-by testing tool to 795-790-1610 measure the pressure in the engine crankcase.
Portable pressure kit This is used to measure the lubricating oil pressure. 795-790-1100
12-16
114 SERIES
SPECIAL TOOL LIST
Tool No. Tachometer
Explanation of tool This is used to measure the engine speed (rpm).
Sketch of tool
799-203-8001
114 SERIES
12-17
TROUBLESHOOTING DE.ECTIVE ACTUATION O. INTAKE AND EXHAUST SYSTEM

CLEAN AIR
To ensure good performance, it is necessary to provide the specified amount of clean air. As explained in the description of the flow in the intake and exhaust systems, dirt or dust sucked in with the air can damage the engine cylinders, and can also damage the valve stems and guides. In addition, it also causes wear of the turbocharger compressor vanes, and this will reduce the efficiency. Large particles of dirt may even break the turbocharger blades. Resistance in the intake circuit is a cause of excessive exhaust smoke and drop in output. The filter is used to filter out the dirt from the intake air, but as the filter becomes dirty, the intake resistance increases. Intake resistance will change the air-fuel ratio, and this will cause drop in output and increase in exhaust smoke. Always make sure that you are carrying out maintenance of the air cleaner properly.
TESTING INTAKE RESISTANCE

If the resistance reaches the maximum permissible limit at engine rated output and rated speed, replace the air cleaner element. 1. Natural aspiration: 4.98 kPa {508 mm H2O} 2. Turbocharger: 6.23 kPa {635 mm H2O}
On engines equipped with a turbocharger, measure the resistance just before the turbocharger. On naturally aspirated engines, measure the resistance just before the intake manifold.
12-18
114 SERIES
DAMAGE CAUSED BY UN.ILTERED AIR

If dirty air enters from cracks in the intake piping at the intake end or looseness of parts in the intake system, dirt or dust will enter the engine and cause premature wear of the cylinder liner. With naturally aspirated engines, dirt or dust may also be taken in through leakage in the intake manifold, unsealed bolt holes, or from the manifold cover gasket.
On engines equipped with a turbocharger, particles entering through cracks or loose connections in the piping at the intake end will enter the turbocharger compressor and will then enter the engine and cause damage.
In such cases, the compressor blades will be damaged, and will lead to loss or balance of the wheel and damage to the bearings. To check if the bearings have failed or the compressor is damaged, remove both the intake and exhaust pipes and check if there is contact between the wheel and housing. The rotor assembly must be able to rotate freely. There must be no damage. Details of the clearance in the axial direction and radial direction will be given later.
LEAKAGE O. SUPPLIED AIR (ENGINES WITH THE TURBOCHARGER)

Excessive exhaust smoke or drop in output on engines equipped with the turbocharger will result from insufficient compression caused by leakage of air from cracks in the intake manifold or crossover tube, or looseness of the pipe connections. This will also cause noise.
114 SERIES
12-19
Check visually for cracks or loose connections. In addition to this, check by coating with soapy water to coat possible locations of leakage, such as the charge air cooler, connections, and seal surface of the manifold cover. Bubbles will form if there is any leak, so it is easy to find leaks by this method. Explanation will be given of the manifold pressure later.
LEAKAGE O. EXHAUST AIR (ENGINE WITH TURBOCHARGER)

Check for leakage of exhaust gas from the exhaust manifold and turbocharger, leakage from the gasket, and the resistance of the exhaust pipe, muffler, and catalyst. If there is leakage or resistance, the rotation of the turbine and impeller will become slower and the amount of air sent to the cylinder will be reduced. In the case also, the symptoms are excessive exhaust smoke, drop in the manifold pressure, and drop in the output.
MEASURING PRESSURE O. TURBOCHARGER AIR (ENGINE WITH TURBOCHARGER)

When measuring the boost pressure, measure at the intake manifold using the intake holes with taps or plugs as shown in the diagram on the right. See the specification page for details. Caution: If there is a charge air cooler, test for leakage from the cooler system and test the resistance of the turbocharger boost pressure to check the condition. .or details of the test of the charge air cooler. Normally, leakage of exhaust gas can be found by listening and checking visually for discoloration caused by hot gas. It must not be forgotten that the resistance of the exhaust gas is a cause of the drop in output. If the exhaust gas does not flow without resistance, the turbocharger will not rotate efficiently.
12-20
114 SERIES
DE.ECTIVE ACTUATION O. TURBOCHARGER (ENGINE WITH TURBOCHARGER)

Damage to the internal parts of the turbocharger will reduce the efficiency of the turbocharger and will cause excessive exhaust smoke and drop in output. Damage to the bearings will cause wear and will reduce the rotating speed of the rotor. In addition , damage to the bearings will cause contact between the rotor assembly blade and housing and will reduce the rotating speed. Defects or mistaken adjustment of the turbocharger exhaust will also cause excessively high or low boost pressure. If the boost pressure is low, it will cause excessive exhaust gas and drop in pressure; if the boost pressure is high, it will cause damage to the engine.
OIL CONSUMPTION AND OIL LEAKAGE

The engine lubricating oil is used lubricate and cool the turbocharger bearings. The oil is supplied to the turbocharger through the supply line by the operating pressure of the engine. The oil is drained to the oil pan through the return line connected to the bottom of the turbocharger.
Seal rings are used at both ends of the rotor assembly, but the main purpose it to prevent exhaust gas or compressed air from entering the turbocharger housing. It is rare for oil to leak from the seal, but it is a possible failure. Caution: If the pressure in the crankcase is excessively high, the oil will not drain from the turbocharger. This pressure will bear on the bearing housing and cause the oil to leak from the compressor seal and enter the engine. On engines equipped with a catalyst, if the leakage from the turbine seal enters the exhaust gas, check the exhaust pressure during repair work. If there is resistance in the oil the return line or the line is damaged, the inside of the housing will become pressurized, and this will cause the oil to leak from the seal.
114 SERIES
12-21
In addition, if the resistance of the intake and exhaust is large, negative pressure will be formed between the housing of the compressor and the housing of the turbine, and this will cause leakage of oil from the seal.
When checking if there is oil leaking from the seal, remove the exhaust pipe and air crossover tube, and check for the existence of oil inside the turbine casing and crossover tube. As explained above, check the resistance and remove the cause.
NOISE .ROM TURBOCHARGER (ENGINE WITH TURBOCHARGER)

The turbine rotates at high speed, so it makes a whining noise. The sound differs slightly according to the engine speed and load. This sound is the noise made by the rotor assembly cutting the air. Therefore, the higher the engine speed is the louder the noise becomes. As far as possible, run the engine at full speed and check what noise is generated.
If there is leakage, the noise from the intake and exhaust components will increase. Pressurize the intake line and check for leakage from the intake inlet port and crossover tube.
12-22
114 SERIES
TROUBLESHOOTING DE.ECTIVE ACTUATION O. INTAKE AND EXHAUST SYSTEM TESTING AND ADJUSTING MEASURING PLAY O. TURBOCHARGER ROTOR IN AXIAL AND RADIAL DIRECTION
Before removing the turbocharger, check if the noise is caused by leakage from the intake or exhaust piston. Loosen the turbocharger mount and check if there is any leakage from the exhaust manifold gasket or any cracks in the exhaust manifold.
If the pitch is low or there is a clattering sound when the engine is running at low speed, there are particles of dirt inside the system or the rotor assembly is contacting the housing.
MEASURING PLAY O. TURBOCHARGER ROTOR IN AXIAL AND RADIAL DIRECTION (ENGINE WITH TURBOCHARGER)
Measuring rotor assembly clearance Measure the clearance in the axial direction of the shaft. Depth gauge (795-790-1800) Play in axial direction (A) Min Max 0.03 mm 0.08 mm
114 SERIES
12-23
MEASURING PLAY O. TURBOCHARGER ROTOR IN AXIAL AND RADIAL DIRECTION TESTING TURBOCHARGER WESTGATE VALVE TESTING AND ADJUSTING
Measuring clearance in radial direction of shaft Clearance in radial direction (B) Min Max 0.21 mm 0.46 mm
If the clearance is greater than the above value, assemble the turbocharger again or replace it.
TESTING TURBOCHARGER WESTGATE VALVE (ENGINE WITH TURBOCHARGER)

Testing
Testing the lever pin. If the wear of the turbine housing assembly is excressive, replace the assembly. .or details of the procedure for reassembly.
Check if the valve and valve seat are cracked or corroded. If the wear of the turbine housing assembly is excessive, replace the assembly. .or details of the procedure for reassembly.
Move the lever by hand and check that shaft rotates freely without catching. Check that there is no excessive movement between the shaft and bushing. If the shaft and bushing are damaged or do not move, replace the turbine housing.
12-24
114 SERIES
TESTING TURBOCHARGER WESTGATE CAPSULE TESTING ACTUATION O. TURBOCHARGER WESTGATE
TESTING TURBOCHARGER WESTGATE CAPSULE (ENGINE WITH TURBOCHARGER)

Testing
Checking visually for cracks or holes in the westgate actuator hose. If there is any damage, replace the hose.
Checking the westgate mounting bracket, actuator rod, and lever visually for damage. If they are bent, the movement will not be correct. If they are bent, replace them.
TESTING ACTUATION O. TURBOCHARGER WESTGATE (ENGINE WITH TURBOCHARGER)

Testing
Using the procedure shown in the diagram, install dial indicator (1) so that its axis is parallel to the Westgate actuator rod. Set so that there is no air pressure acting on the Westgate capsule, then set the indicator to 0. Connect clean, adjusted air pressure and pressure gauge (2) to the capsule. Apply pressure at 103 kPa {1.05 kg/cm2} and check that the Westgate functions properly. The rod must move approx. 5 mm without scuffing or leakage of air. Caution: There must be no sound of leaking air from the Westgate capsule when it functions. Caution: When air is first applied, it will move slightly. This is not an abnormality.
114 SERIES
12-25
TESTING ACTUATION O. TURBOCHARGER WESTGATE REPLACING TURBOCHARGER WESTGATE ACTUATOR BOOST CAPSULE
If the actuator rod and lever do not move, replace the actuator.
REPLACING TURBOCHARGER WESTGATE ACTUATOR BOOST CAPSULE (ENGINE WITH TUBOCHARGER)

Replacing
Caution: Before removing, note down the position and length of the connecting rod from the boost capsule housing and its direction in relation to the mounting bracket of the boost capsule hose connector. Pressure test kit (795-790-1700) Remove the stopper clip from the control lever.
Remove the tip of the boost capsule actuator rod from the turbocharger westgate lever. When carrying out this operation, apply adjusted air pressure sufficient to move the boost capsule connecting rod. Remove the connecting rod from the turbocharger westgate lever pin. Caution: Be careful not to bend the control lever. Caution: If the diaphragm is broken or the air pressure can only be maintained by hand, turn the connecting rod to the outside and pull by hand to overcome the force of the spring, then remove the connecting rod from the lever pin.
12-26
114 SERIES
REPLACING TURBOCHARGER WESTGATE ACTUATOR BOOST CAPSULE
Loosen the capsule mounting bolts, then remove the air supply hose and remove the assembly from the mounting bracket.
Remove the tip of the adjustment link from the actuator.
Install the tip of the adjustment link to the new actuator assembly at the position from which it was removed.
Install the new actuator assembly to the actuator mount bracket, then tighten the mounting bolts. 3 Mounting bolt: 4.5 Nm {0.46 kgm}
114 SERIES
12-27
ADJUSTING TURBOCHARGER WESTGATE ACTUATOR
ADJUSTING TURBOCHARGER WESTGATE ACTUATOR (ENGINE WITH TURBOCHARGER)

Adjusting
Caution: The westgate is set accurately at the factory. It is unnecessary to adjust it if the capsule is not removed. Apply adjusted normal air pressure to boost capsule (2). Using table below, use air pressure to match the westgate capsule. Rated All Pressure 191 kPa {1.9 kg/cm2}
Measure stroke A of the actuator. The specified measurement for the Westgate is 0.33 - 1.3 mm. Caution: Do not push, pull, or apply force to the alignment of the clevis pin. If necessary, adjust the westgate to set to the specified stroke. Pull the westgate lever until it is almost closed (set the lever facing in the direction of the boost capsule). Adjust the length of the connecting rod clevis end, then align the hole in the clevis pin with the center of the westgate lever. Install the adjustment link and stopper clip. After completing the adjustment, tighten the actuator rod stopper nut. Remove the adjustment air pressure line from the boost capsule. Connect the turbocharger boost line to the boost capsule, then secure with the hose clamp. If possible, carry out adjustment of the westgate using a more accurate method. With this method, check the manifold pressure at the rated rpm in accordance with the turbocharger boost pressure specifications.
12-28
114 SERIES
MEASURING EXHAUST RESISTANCE REPLACING TUBOCHARGER (ENGINE WITH TURBOCHARGER)
MEASURING EXHAUST RESISTANCE

Install a pressure gauge (795-790-1470) to the inlet port where the pressure tap of the exhaust head pipe passes through to the catalyst/muffler assembly. Run the engine at rated speed and no load, and note the exhaust resistance.
If the resistance exceeds the specification, check the oxidizing catalyst and/or muffler, and replace. Industrial use: 10.13 kPa {76 mmHg} Oxidizing catalyst equipment (94 EPA certification): 20.26 kPa {152 mmHg}
REPLACING TUBOCHARGER (ENGINE WITH TURBOCHARGER)

Cleaning and testing
Clean the seal surface. Check for damage to the seal surface and mounting stud.
Caution: If you are not going to replace the turbocharger immediately, block the opening to prevent dust from entering the manifold. Check the turbocharger westgate link, valve shaft, module, and pressure signal line. Check and adjust the westgate.
114 SERIES
12-29
TROUBLESHOOTING DE.ECTIVE ACTUATION O. ENGINE

VALVE MECHANISM AND CYLINDER HEAD
If noise comes from the overhead, there is a problem in the valve train. If the rocker lever is loose, it will make a clattering noise. A squeaking noise indicates lack of oil on the adjustment screw or push rod socket.
Caution: When removing any of the support pedestals during inspection or restoration work, carry out tightening of the head bolts in the set order.
TESTING AIR SYSTEM AND .UEL SYSTEM

When carrying out troubleshooting of problems with lack of output, first carry out troubleshooting of the air system and fuel system to check that there is sufficient fuel and intake air for the engine.
Check for leakage from the intake system. Check that there is sealant coated on the mounting bolt in the through hole securing the manifold cover to the head. Check that the turbocharger is working correctly.
12-30
114 SERIES
Check that the fuel system timing and fuel supply is correct.
TESTING VALVE CLEARANCE

Check that the valves are correctly adjusted.
TESTING COMPRESSION
If the air system and fuel system are working correctly, check the compression. Locate the cause from the following problems. Piston ring sealing Valve sealing Cylinder head gasket sealing or cracks in cylinder head
PISTON RING SEALING PER.ORMANCE

If the compression rate is low but it is possible to make it fairly high by supplying oil to the cylinder, there is insufficient sealing between the piston ring and the surface of the cylinder wall, so the compression will drop.
114 SERIES
12-31
VALVE SEALING PER.ORMANCE

If the compression rate of 2 or more cylinder which are not next to each other is low, and the pressure does not rise even when oil is supplied to the ring, it can be judged that the valve sealing is poor.
The sound of valve leakage can be easily heard from the intake and exhaust manifold.
The original valve seat can be ground again to a depth of 0.254 mm. After regrinding the valve seat, mark the cylinder head to distinguish it. If the valve seat has already been ground again, replace the valve seat with a new part.
HEAD GASKET SEALIN PER.ORMANCE

If the compression of the neighboring cylinder is low and the pressure does not rise even when oil is supplied to the ring, there may be leakage from the head gasket between the cylinders.
12-32
114 SERIES
If the compression is defective for only one cylinder, the cause is external leakage or leakage to the cooling water passage.
If there is leakage of compression gas to the cooling water, this problem can normally be seen because the cooling water is pushed up from the cooling system and the cooling water level goes down.
External leakage from the cylinder head gasket can be checked visually. The easiest way to check for external leakage is to use soapy water.
VALVE SEAL WEAR

Generally speaking, wear of the valve seal can be immediately recognized by excessive exhaust smoke when the engine is running at low idling or when the machine travels downhill under no load. Remove the valve spring, checking the valve seal, and confirm its condition.
114 SERIES
12-33
Leakage from the valve seal will occur when the seal material becomes hard or when the seal surface is worn or damaged.
PROTRUDING PORTION O. .UEL INJECTION NOZZLE

The protruding portion of the injector has an effect on the engine output. In addition to single sealing washer (A) of the injector, the thickness (B) of the head gasket also controls the protruding portion of the injector.
When grinding to correct the cylinder block head surface, use a thicker service head gasket.
After machining, distinguish the cylinder head as follows. Machining A - Standard B - Machine 0.25 mm for the 1st oversize gasket C - Machine 0.25 mm for the 2nd oversize gasket [Total: 0.50 mm] Mark None
12-34
114 SERIES
When the machining amount has been achieved, look at the parts catalog and select a suitable oversize head gasket.
.RONT GEAR HOUSING AND GEAR TRAIN

When carrying out troubleshooting of the front gear housing and gear train, Carry out the following checks as necessary: check for leakage from the gasket (front cover, timing pin assembly, fuel pump) and front crankshaft oil seal, check the gears, and check the back clearance.
If gear noise can be heard from the cover, the gear teeth are worn. Caution: If the back clearance is excessive, it will also affect the engine timing and engine performance.
As explained in the section on the fuel system, when replacing the gear housing and timing pin assembly, set the No.1 cylinder to TDC and align the housing pin assembly. .or detailed explanation of the replacement procedure.
114 SERIES
12-35
ROCKER LEVER, VALVE STEM, PUSH ROD, TAPPET, AND CAMSHA.T

If the valve lash is excessive, the valve stem or rocker lever are worn.
If the rocker lever is loose or it is necessary to adjust the valve clearance frequently, the camshaft lobe or tappet are worn. If the lever, valve stem, or push rod are inspected and they are not worn, there may be wear of the tappet and/or camshaft lobe.
Caution: When installing a new camshaft, install new tappets also. The camshaft lobe can be inspected visually if the oil pan is removed. In the same way, the tappet surface can also be checked by removing the push rod and lifting up the tappet.
Excessive damage to the camshaft journal will occur when there are metal particles in the oil pan or oil filter. If the clearance between the bushing and journal increases, the oil pressure may drop.
12-36
114 SERIES
PISTON AND CONNECTING ROD

If the sealing between the piston ring and surface of the cylinder liner wall is defective, there will be various problems related to the output, such as excessive oil consumption, exhaust smoke and blow-by, and drop in the engine performance. It is easy to recognize the existence of problems by measuring the blow-by.
When checking for wear or damage to components, check the rings, piston, and cylinder bore visually and check the dimensions.
There are various causes of piston ring wear, ranging from long-term use to short-term accumulation of dirt resulting from poor maintenance of the intake system.
During repair work, to make the new ring fit the cylinder wall properly, always remove the luster from the cylinder liner. If the ring contact is not correct, the blow-by will increase and this will lead to increased oil consumption.
114 SERIES
12-37
After removing the luster, it is important to clean the cylinder liner wall thoroughly. If any grit remains on the cylinder liner wall it will cause rapid wear of the new ring, and this will lead to problems with the output as explained above.
If the engine overheats because of lack of cooling water, the cylinder liner will overheat and this will cause seizure of the piston. If there is lack of cooling oil for the piston, the piston will also seize.
Improper maintenance of the lubrication system is a main cause of reduction in the life of the main bearing.
Normally, It is possible to recognize wear of bearing because the oil pressure goes down. However, if you do not notice the wear, the clearance will become larger and this will cause the connecting rod to hit the crankshaft, so knocking will be heard.
12-38
114 SERIES
Knocking of the connecting rod occurs when the engine is running under no load. .irst, apply load, then run under no load to check if you can hear any knocking.
CRANKSHA.T AND MAIN BEARING

Improper maintenance of the lubrication system is a main cause of reduction in the lift of the main bearing. Normally, It is possible to recognize defective operation of the crankshaft/main bearing because of the oil pressure goes down. In the same way as with the rod bearing, if the engine is run continuously at low oil pressure, the bearing will deteriorate rapidly and this will cause knocking.
With the main bearing, the knocking noise can be heard when the engine is running under a load.
It is possible to recognize damage, wear, or loss of the thrust bearing flange of the top main bearing shell by measuring the play of the crankshaft in the axial direction. Limit for play in axial direction Min Max 0.085 mm 0.385 mm
114 SERIES
12-39
If there is any defect in the driven component at the front or rear of the engine, the load in the axial direction will increase and this will damage the thrust bearing.
CYLINDER BLOCK
Details of the method for troubleshooting defective actuation of the cylinder block related to the cooling system and lubricating system has been given in the respective sections. The explanation given here is for problems with the cylinder, camshaft bore, and crankshaft main journal.
When checking for leakage, wear of the tappet bore, or other defective actuation of the cylinder block, check visually and check the dimensions to distinguish the problem.
12-40
114 SERIES
.LYWHEEL HOUSING AND .LYWHEEL

Normally, troubleshooting of the flywheel housing and flywheel is carried out by visual inspection of damage or wear to the parts.
Breakage of the ring gear teeth may occur because of defective actuation of the starting motor. A service ring gear can be used for repair of the flywheel (see Section 7-23).
When carrying out troubleshooting for vibration of the transmission, it is necessary to measure the concentricity of the flywheel housing and flywheel and to measure the alignment of the flywheel housing rear face.
114 SERIES
12-41
ADJUSTING VALVE CLEARANCE

Remove the valve cover (1).
1/2 inch drive, gear (795-799-1130)

Push the engine timing pin and carry out barring of the crankshaft slowly to set the No.1 cylinder to top dead center (TDC).
When the timing pin (2) is meshed with the hole in the cam shaft gear (3) the No.1 cylinder is at compression TDC.
Caution: To prevent damage to the engine or timing pin, check if the meshing of the timing pin has been removed after positioning at TDC.
12-42
114 SERIES
Clearance gauge
Intake clearance: 0.30 mm Exhaust clearance: 0.56 mm Let the engine cool down before checking or installing the valves - max. 60C Caution: When sliding the clearance gauge between the valve stem and rocker lever, the clearance is correct if some resistance is felt.
ADJUSTING 6-CYLINDER ENGINE

14 mm, flat-head screwdriver
Set the No. 1 cylinder to top dead center (TDC). Check and adjust the valve as shown in the diagram (I = intake, E = Exhaust) Tighten the locknut and measure the back clearance again. 3: 24 Nm {2.45 kgm}
Make a mark on the pulley and turn the crankshaft 360. Caution: To prevent damage to the engine or pin, check that the timing meshing has been removed.
Adjust the valve as shown in the diagram. Tighten the locknut and measure the back clearance again. 3: 24 Nm {2.45 kgm}
114 SERIES
12-43
15 mm
Install the valve cover (1) and tighten the mounting bolts. 3: 24 Nm {2.45 kgm}
12-44
114 SERIES
TROUBLESHOOTING DE.ECTIVE ACTUATION O. LUBRICATING SYSTEM

OUTLINE
When carrying out troubleshooting, check the gauges, high or low level of the oil, excessive consumption of oil, oil viscosity, and the various items related to the oil pressure.
HIGH PRESSURE
High oil pressure generally occurs immediately after starting in cold areas. Generally speaking, the starting pressure in approx. 552 - 689 kPa {5.6 - 7.0 kg/ cm2}. If the pressure adjustment plunger works properly, when the normal operating temperature is reached, the pressure goes down to approx. 449 kPa {4.6 kg/cm2}.
REGULATOR VALVE
If the regulator sticks at the closed position, the oil pressure will rise at the normal operating temperature. Check that the regulator is moving freely.
114 SERIES
12-45
LOW PRESSURE
Defective operation of the equipment related to the lubricating system is a cause of low oil pressure (or no pressure). When low pressure is first observed, that is after the service interval, the first step in investigating is to know the operating condition of the engine at idling only and when traveling uphill.
OIL LEVEL
If the oil level is too high, it will cause low pressure. If the oil level is high enough for the connecting rod to be submerged in the oil during operation, air will mix with the oil and this will cause low oil pressure. Low oil level is normally shown by low oil pressure.
Generally speaking, with low oil level, the oil pressure is intermittently lost when traveling around corners or when traveling uphill. In there conditions, the oil level becomes extremely low and oil does not flow in the suction tube in any working mode.
OIL .ILTER
If the filter becomes clogged, the oil pressure will gradually go down until it reaches approx. 69 kPa {0.7 kg/cm2}. When the filter bypass valve is opened, the oil pressure returns to normal. If it does not return to normal, unfiltered oil flows to the engine when the bypass valve is open and the engine will suffer wear. 2. Gradually goes down 3. Suddenly returns to normal 4. Replace
12-46
114 SERIES
OIL PRESSURE GAUGE

Check the oil pressure with the manifold gauge and check the oil pressure gauge and supply portion to confirm that they are working normally.
OIL PAN SUCTION TUBE

If the suction tube inside the oil pan becomes loose or the gasket is damaged, or the tube is cracked, the actuation of the oil pump will become temporarily defective. When starting the engine, the oil pressure is low or stays at 0, but usually it will return to the normal value as time passes.
BEARING AND OIL PUMP

If the oil pressure gradually goes down over (see 5) a long time, it means that the bearing (2) is worn or the oil pump (3) is worn.
DILUTION O. OIL
Caution: Dilution of the oil will cause serious damage to the engine. Check the condition of the oil. If the viscosity is low and the oil is black, there is fuel mixed in the oil. If the oil is milky white, there is cooling water mixed in the oil. 6. .uel is diluted (thin black color) 7. Good oil 8. Water in oil (milky color)
114 SERIES
12-47
The causes of cooling water getting into the oil are as follows: Leakage from the cup plug Leakage from the oil cooler element Damage to the head or gasket Cracks in the block Casting holes
COOLING WATER IN OIL

The design of the oil cooler does not require a gasket or seal to separate the oil and cooling water, so the element itself causes leakage of cooling water.
When the engine is running, the oil pressure is higher than the water pressure. Therefore, if there is leakage from the oil cooler, the oil mixes with the water. When the engine stops, the residual pressure in the cooling circuit makes it possible for the cooling water to mix with the oil.
When checking dor leakage pressurize the cooling circuit to 140 kPa {1.4 kg/cm2}. When pressurizing, remove the following components and check for leakage. Valve cover (if there is leakage, there are cracks in the cylinder head) Oil drain plug (if there is leakage, the oil cooler or head gasket is defective or there are cracks in the cylinder head or block)
12-48
114 SERIES
The entry of cooling water into the oil is caused by damage to the head gasket or by cracks in the head or block. Remove the head and gasket, and check for cracks or damage.
.UEL IN OIL
Dilution by fuel is caused by one of the following five problems. 9. .uel dilution 1. Defective shaft seal on injection pump 2. Leakage of fuel from ring 3. Defective fuel feed pump 4. Crack reaching from position of fuel filter on head to intake port 5. Leakage from injector
Use the following chart to search for the cause of dilution of the oil by fuel. Excessive white smoke when starting
Drop in output
Drop in output
Excessive black smoke
Normal output
Check, replace injector
Test compression and check ring sealing
Check for leakage from fuel feed pump
Replace fuel pump seal
114 SERIES
12-49
The unused fuel inside the cylinder drops into the oil pan and is drained. This problem is caused by defective compression because of the leakage from the injector or the poor sealing of the piston ring.
When starting the engine at the beginning of the day, If there is excessive white smoke, it show that there is leakage from the injector. Leakage from the injector or failure of the engine to rotate smoothly is also a cause of low output. In such cases, remove the injector, and repair or replace.
To test the sealing of the piston ring, check the cylinder compression.
If the element in the oil cooler breaks, the oil will mix with the cooling water because of the pressure of the oil. Oil in the cooling water can be detected when the radiator cap is removed.
12-50
114 SERIES
Wear of damage of the turbocharger seal will cause leakage of oil to the air crossover pipe, and the oil may be sucked in and burn together with the fuel. If this happens, it is possible to check by removing the air crossover tube or charge air cooler piping and looking for oil.
Defective sealing of the piston ring causes oil to spurt from the breather tube or results in abnormal consumption of oil.
114 SERIES
12-51
FUEL INJECTION PUMP CALIBRATION DATA

Engine model Pump assembly No. 6743-71-1122 6743-71-1131 Engine serial No. Applicable machine WA380-5 PC300-7, CD110R-2 Page 12-53 12-54
SAA6D114E-2
12-52
(3)
114 SERIES
Injection Pump Assembly Number

6743-71-1121 (4063538) 6743-71-1122 (4063700) ( ): Injection Pump Manufactures part No. Injection Pump Type P3000 Injection Pump Manufactuer Bosch Applicable Machine Model WA380-5 Serial No. Applicable Engine Model SAA6D114E-2 Serial No.
Injection Pump Specification

Rotating direction Injection order Injection interval Plunger prestroke (mm) Clockwise 153624 60 0.75 3.6 0.1 120
Engine Specification
Flywheel horsepower (kW {HP}/rpm) 151.5 {203}/2,000 (Gross) Max. torque High idling speed Low idling speed Test stand capacity ( ): Injenction pump manufactures part number Service standard Manufacturer standard 6743-11-3201 (4063526) (DLLA140PV318983) 6.30 3.0 600 6.35 1.8 740 (Nm {kgm}/rpm) (rpm) (rpm) 945 {96.4}/1,400 (Gross) 2,250 50 920 + 50 0 Motor: 7.5 kW
Delivery valve (mm3/st) retraction volume
Calibration Standard
Conditions Service standard indicates data using calibration test parts. Manufacture standard is data for factory test parts. Nozzle & Nozzle holder part No. Nozzle part No. Nozzle holder part No. Injection pipe (Outside dia. x Inside dia. x Length) Test oil Oil temperature (C)
Nozzle opening pressure (MPa {kg/cm2}) Transfer pump pressure (kPa {kg/cm2})
(1688901103)
(mm)
ASTM D975 No.2 diesel fuel or equivalent 40 20.7 + 0.3 {211 + 3} 200 {2.04} Service standard (cc/1,000 st) Manufacturer standard (cc/1,000 st) Injection volume Maximum variance between cylinder Maximum variance between cylinder 30 + 1.0 {306 + 10}
Injection volume Rack point Rack positions B to E are the A(Basic point) refernce volume B when adjusting the injection volume. C Marks 5 are averD age volumes. E Governor perfomance curve Rack position (mm) Pump speed (rpm)
Injection volume
Boost compensator performance curve
114 SERIES
12-53
1
Injection Pump Assembly Number

6743-71-1131 (4063536) ( ): Injection Pump Manufactures part No. Injection Pump Type P3000 Injection Pump Manufactuer Bosch Applicable Machine Model PC300-7 CD110R-2 Serial No. Applicable Engine Model SAA6D114E-2 Serial No.
Injection Pump Specification

Rotating direction Injection order Injection interval Plunger prestroke (mm) Clockwise 153624 60 0.75 3.6 0.1 120
Engine Specification
Flywheel horsepower (kW {HP}/rpm) Max. torque High idling speed Low idling speed Test stand capacity ( ): Injenction pump manufactures part number Service standard Manufacturer standard 6743-11-3101 (4063524) (DLLA140PV3189125) (mm) (1688901103) 190 {254}/1,900 (Gross)
(Nm {kgm}/rpm) 1,110 {113}/1,400 (Gross) (rpm) (rpm) 2,180 50 900 25 Motor: 7.5 kW
Delivery valve (mm3/st) retraction volume
Calibration Standard
Conditions Service standard indicates data using calibration test parts. Manufacture standard is data for factory test parts. Nozzle & Nozzle holder part No. Nozzle part No. Nozzle holder part No. Injection pipe (Outside dia. x Inside dia. x Length) Test oil Oil temperature (C)
Nozzle opening pressure (MPa {kg/cm2}) Transfer pump pressure (kPa {kg/cm2})
6.30 3.0 600 40 20.7 + 0.3 {211 + 3} 200 {2.04} Service standard (cc/1,000 st) Injection volume Maximum variance between cylinder
6.35 1.8 740
ASTM D975 No.2 diesel fuel or equivalent 30 + 1.0 {306 + 10} { } Manufacturer standard (cc/1,000 st) Injection volume Maximum variance between cylinder
Injection volume Rack point Rack positions B to E are the A(Basic point) refernce volume B when adjusting the C injection volume. Marks 5 are averD age volumes. E Governor perfomance curve
Rack position (mm)
Pump speed (rpm)
Boost compensator performance curve
12-54
(3)
114 SERIES
RUNNING IN STANDARD
RUNNING IN STANDARD
Engine model Applicable machine Item Running time PC300-7 Engine speed CD110R-2 Load Running time WA380-5 SAA6D114E-2 Engine speed Load Running time GD655-3A Engine speed GD655-3C Load Running time GD675-3A Engine speed GD675-3C Load Running time Engine speed Load Running time Engine speed Load Running time Engine speed Load Running time Engine speed Load min. rpm N{kg} min. rpm N{kg} min. rpm N{kg} min. rpm N{kg} min. rpm N{kg} min. rpm N{kg} min. rpm N{kg} min. rpm N{kg} Order 1 2 900 0(0) 0(0) 2 920 0(0) 0(0) 2 825 0(0) 0(0) 2 825 0(0) 0(0) 2 10 1,000 98(10) 7(10) 10 1,000 98(10) 7(10) 10 1,000 98(10) 7(10) 10 1,000 98(10) 7(10) 3 2 1,200 245(25) 22(30) 2 1,200 245(25) 22(30) 2 1,200 245(25) 22(30) 2 1,200 245(25) 22(30) 4 3 1,600 76(103) 3 1,600 76(103) 3 1,600 76(103) 3 1,600 637(65) 76(103) 5 1,200 1,900 185(247) 1,200 2,000 152(203) 1,200 1,900 147(197) 1,200 1,900 1,080(111) 154(207) 6
637(65) 1,294(132)
Flywheel horsepower kW{HP}
637(65) 1,010(103)
637(65) 1,030(105)
5 This table shows the standard values for the engine without fan. 5 The loads for the dynamometer in this table are at an arms length of 716 mm.
114 SERIES
12-101
(3)
PERFORMANCE TEST CRITERIA

5 This table gives the standard values using the JIS correction factor. 5 The outputs and torques in this table are the standard values when the fan is removed, so they are different from the specification values. 5 This table shows the standard for a machine with an air cleaner installed, alternator under no load, and air compressor (if equipped) open. 5 The loads for the dynamometer are at an arm's length of 716 mm. Engine model Applicable machine Test item Flywheel horsepower Max. torque High idling speed Low idling speed Flywheel horsepower Max. torque WA380-5 High idling speed Low idling speed Flywheel horsepower Max. torque High idling speed Low idling speed Flywheel horsepower Max. torque High idling speed Low idling speed Flywheel horsepower Max. torque High idling speed Low idling speed Specifications 180kW/1,900rpm {242HP/1,900rpm} (Net) 1,078Nm/1,400rpm {110kgm/1,400rpm} (Net) 2,180 50rpm 900 25rpm 140kW/2,000rpm {187HP/2,000rpm} (Net) 883Nm/1,400rpm {90kgm/1,400rpm} (Net) 2,250 50rpm 920 + 50rpm 0 147kW/1,900rpm {197HP/1,900rpm} (Gross) 940Nm/1,400rpm {96kgm/1,400rpm} (Gross) 2,225 50rpm 825 50rpm 154kW/1,900rpm {207HP/1,900rpm} (Gross) 989Nm/1,400rpm {101kgm/1,400rpm} (Gross) 2,225 50rpm 825 50rpm Engine Speed Dynamometer (rpm) N{kg} 1,900 5 1,400 100 2,180 50rpm 900 25rpm 2,000 5 1,400 100 2,250 50rpm 920 + 50rpm 0 1,900 5 1,400 100 2,225 50rpm 825 50rpm 1,900 5 1,400 100 2,225 50rpm 825 50rpm { { { }
PC300-7 CD110R-2
{ {
SAA6D114E-2
GD655-3A GD655-3C
GD675-3A GD675-3C
12-120
(3)
114 SERIES
5 For fuel, use JIS No. 2 diesel oil. 5 For lubricant, use SAE30 oil.
Flywheel Torque horsepower Nm(kgm) kW(HP) { } (Gross) { } (Gross) { } (Gross) { } (Gross)
Fuel consumption (sec/100cc)
Cooling water Lubricating oil Lubricating oil Exhaust temperature temperature pressure temperature ( C) ( C) kPa{kg/cm2} (C) Min. 83 95 Max. 550 80 110 343 588 {3.5 6.0} 83 83 83 Min. 83 83 83 83 Min. 70 70 70 70 Min. 70 70 70 70 95 95 95 95 95 95 95 90 90 90 90 90 90 90 90 80 80 80 80 80 80 80 90 90 90 80 90 90 90 80 110 110 110 110 110 110 110 110 110 110 110 110 110 110 110 343 {3.5 343 {3.5 588 6.0} 588 6.0} Max. 550
{ } (Gross)
Min. 147 {Min. 1.5} 343 588 {3.5 6.0} 343 {3.5 343 {3.5 588 6.0} 588 6.0}
Max. 550 Max. 550
{ } (Gross)
Min. 147 {Min. 1.5} 290 490 {3.0 5.0} 290 {3.0 290 {3.0 490 5.0} 490 5.0}
Max. 650 Max. 650
{ } (Gross)
Min. 120 {Min. 1.2} 290 490 {3.0 5.0} 290 {3.0 290 {3.0 490 5.0} 490 5.0}
Max. 650 Max. 650
{ } (Gross)
Min. 120 {Min. 1.2}
114 SERIES
12-121
(2)
TESTING .UEL .EED PUMP

Disassembly/assembly drawing (cylinder block installation type)
A. Low flow B. High flow
Part No. 1 2 3 4 5
Part Name Check valve Check valve gasket O-ring O-ring Outlet check valve
Quantity 2 2 1 3 1
12-140
114 SERIES
DISASSEMBLY AND ASSEMBLY O. .UEL .EED PUMP

DISASSEMBLY
20-mm, 26-mm wrench Caution: There are springs assembled in the hand priming joint and inlet joint. If these two joints are removed suddenly, there is danger of injury. Taking care not to damage the pump housing, fix the pump in a vice. Remove the rubber cover from the hand priming joint.
Use the procedure in the diagram to remove the 3 joints. (A) Outlet joint (B) Inlet joint (C) Hand priming joint Remove all the components inside the pump. Caution: Check that the check valve gasket is removed from the inlet joint.
Washing
Wash the pump thoroughly in detergent to remove any dirt stuck to the pump. Caution: Normally, it is possible to polish the pump port lightly.
ASSEMBLY
20-mm, 26-mm wrench Assemble the pump using the new components in the disassembly repair kit. 1. Check valve 2. Check valve gasket 3. O-ring 4. Outlet fitting, check valve 5. O-ring (25 mm) 6. O-ring (25 mm or 30 mm) 5 The necessary O-ring is decided by the size of the inlet joint. Dispose of the O-ring that is not used.
114 SERIES
12-141
Caution: Check that the check valve is installed so that it opens in the direction of the fuel flow. If the direction of installation of the check valve is mistaken, the performance will drop.
.ix the pump in a vice and tighten the joints. 3 Joint: (A) Outlet joint: 30 Nm {3.06 kgm} (B) Inlet joint: 30 Nm {3.06 kgm} (C) Hand priming joint: 30 Nm {3.06 kgm}
12-142
114 SERIES
ADJUSTING .UEL CUT-O.. SOLENOID

DIRECTION O. .UEL CUT-O.. SOLENOID
All the 114 Series engines mounting a fuel cut-off valve solenoid use either a synchrostart or trumpeter solenoid. Caution: To prevent failure due to moisture, the trumpeter solenoid valves all face in the 6 oclock direction as specified below.
Check that there is no dirt, damage, or other problem in any part or at any mounting point. There must be no rust on the plunger.
Set the solenoid shaft facing the fuel injection pump, then pass it through the bracket and insert it. Check that the air bleed hole in the rubber bellows is is at the 6 oclock position.
Push the solenoid by hand and align with the mounting bolt hole. It is not shown in the diagram, but this operation is necessary to align the plunger on top of the shut-down lever.
114 SERIES
12-143
Insert the mounting bolt into the solenoid, then push in the bracket by hand.
Tighten the bolt.
3 Bolt: 10 Nm {1.0 kgm} Connect the wiring harness.

Synchrostart
This operation is to carry out maintenance and adjustment of the synchrostart fuel cut-off solenoid used to stop the Bosch A/RSV fuel injection pump. Caution: The same procedure is also used for adjusting the trumpeter, so see the procedure on the following page.
8 mm
As shown in the diagram, adjust the solenoid mounting bracket so that the solenoid plunger shows the center of the shut-off lever. 3 Solenoid mounting bolt: 10 Nm {1.0 kgm}
12-144
114 SERIES
Start the solenoid and check the movement of the plunger. The length of the stroke at the pulling-in position must be set so that the clearance between the adjustment screw and the shut-off lever (full run position) is a maximum of 1 - 3 mm. The length of the plunger can be adjusted by tightening or loosening the adjustment screw by hand.
Stop the solenoid and check the movement of the plunger. The plunger must extend to a point where the shut-off lever contacts the shut-down stop screw. If necessary, adjust the adjustment screw so that the shut-off lever contacts the stop screw.
Turn the starting switch ON and check the movement of the plunger. 1. Synchrostart A = 86.6 mm B = 60.2 mm 2. Trumpeter A = 91.4 mm B = 63.5 mm
The fuel cut-off solenoid must be actuated, and at travel position (B), the plunger must always be pulled in. The fuel cut-off solenoid must always operate smoothly.
INSTALLATION O. MECHANICALLY OPERATED SOLENOID, CYLINDER BLOCK

Remove the solenoid link from the lever. Turn the starting switch ON and check the movement of the plunger. Measure distance (B) from the center of the ball socket to the solenoid mounting flange. B = 117.1 mm The fuel cut-off solenoid must be actuated, and at travel position (B), the plunger must always be pulled in. The fuel cut-off solenoid must always operate smoothly.
114 SERIES
12-145
TESTING .OR AIR INSIDE THE .UEL SYSTEM

If the fuel supply line, fuel filter, fuel injection pump, fuel injection pipe, or fuel injection nozzle are replaced, air will enter the fuel system. Use the specified procedure to bleed the air from the fuel system.
With the fuel feed pump, the normal pressure is applied to the fuel injection pump through the fuel filter and fuel supply line, so if the connection is loosened or the seal is missing, the fuel will leak.
The inlet port of the fuel feed pump and the suction tube of the fuel tank are places where it is easy for air to get into the fuel system. The fuel tank has a fuel outlet port fitting at the top, and the suction tube extends from this. If there is any crack or pin hole in the weld connecting the tube to the fitting, air will enter the fuel system.
If air enters the fuel system, it will be difficult to start the engine, the engine rotation will not be smooth, there will be defective ignition, or the engine output will be low, and it will cause excessive smoke and fuel knocking.
12-146
114 SERIES
A jump-over tube is installed to the Bosch P3000 fuel injection pump. The return fuel and air flows from the pressure release valve directly to the fuel tank.
With the Nihon Denso EP-9 in-line fuel injection pump, before first starting or after replacing the fuel injection pump, or if the engine has run out of fuel, the air must be bled when running the engine. A. Manual type air bleeder B. Control type air bleeder
114 SERIES
12-147
TESTING WATER SEPARATOR, .UEL .ILTER
TESTING WATER SEPARATOR, .UEL .ILTER

To operate the machine without failure and to extend the service life of the fuel system, it is important to filter and separate the water from the fuel. The clearance between the components of the fuel injection pump is extremely small in some cases. .or that reason, there is danger of damage being caused by rust or dirt. 5 Check that the proper element is being used.
There is a valve installed to the element. Open this valve periodically and drain the accumulated water.
The dual water separator or filter adapter have filtering capacity. The fuel passes through the adapter, flows through a large assembly type fuel and water separator filter, returns to the fuel filter, and is finally filtered.
In order to remove the water from the fuel, it is necessary to periodically drain the moisture from the fuel and water separator, the filter, or the fuel tank.
12-148
114 SERIES
TESTING HIGH-PRESSURE .UEL PIPING
TESTING HIGH-PRESSURE .UEL PIPING

Caution: .ix the high-pressure line securely in position and arrange the piping so that the pipes do not touch each other or other parts. The high-pressure fuel line is designed to send fuel to the fuel injection nozzle at the injection pressure. The high-pressure valve expands and contracts the line during the injection cycle.
Do not weld the fuel injection pipe or use any substitute. Use only the part numbers that are specified for the engine model. The length of the pipe, internal dimensions, and rigidity are important elements for smooth operation of the engine. Check the metal tags and use the part numbers to distinguish the pipes.
Caution: The pressure of the fuel in the fuel injection pipe will pierce your skin, so there is danger that it may cause serious injury. Use cardboard when checking for cracks or leakage. Run the engine and move the cardboard above the fuel line to check the spray of fuel against the cardboard. If any fuel leakage occurs, the engine performance will drop.
114 SERIES
12-149
TESTING HIGH-PRESSURE .UEL PIPING TESTING .UEL INJECTION NOZZLE
Normally, air enters the fuel piping when the fuel injection pump or fuel piping related parts are replaced. If there is air in the piping, the engine rotation will not be smooth and it will cause fuel knocking.
Bleed the air from the high-pressure piping from the fitting connected to the fuel injection nozzle. Bleed the air from one cylinder at a time until the engine rotation becomes smooth. If the air cannot be removed, check for air being sucked into the fuel injection pump and fuel supply line.
TESTING .UEL INJECTION NOZZLE

Caution: Use only the specified fuel injection nozzle that matches the engine. The engine uses a sealed nozzle, hole type fuel injection nozzle. The part number for the fuel injection nozzle differs according to the rating of the engine. Use the last four digits of the part number for the nozzle to distinguish the fuel injection nozzle.
During the fuel injection cycle, the high-pressure from the fuel injection pump raises the actuating (pump) pressure, and lifts up the needle valve inside the fuel injection nozzle. .uel is injected into the cylinder. When the fuel injection pressure fuel injection pressure goes below the pump pressure, a spring with shim closes the needle valve, and seals the nozzle after the fuel is injected.
12-150
114 SERIES
TESTING .UEL INJECTION NOZZLE
If the needle valve is not raised or close at the correct time, or if the needle valve stays open and does not move, there will be improper ignition and the engine output will go down. If the fuel injection nozzle stays open and fuel leaks, it will cause fuel knocking, drop in performance, smoke, increase in fuel consumption, and lack of smooth rotation of the engine.
To determine if there is improper ignition in any cylinder, start the engine, loosen the nut of the fuel injection pipe for one of the cylinders, and listen for any change in the engine speed. If the engine speed drops, the fuel injection nozzle is sending fuel properly to that cylinder. Check all the cylinders in turn to locate the fuel injection nozzle which is not working properly. Before going on to the next fuel injection nozzle, check that the nut of the present fuel injection pipe has been properly tightened.
Remove the fuel injection nozzle which is not working properly and test or replace it. If the defective ignition in the engine is not corrected even when the fuel injection nozzle is replaced, check for leakage in the fuel injection pipe system. Check also for defects in the delivery valve draining the fuel back to the fuel injection pump.
If carbon accumulates in the orifice in the fuel injection nozzle, the engine output will drop. Remove the fuel injection nozzle and check the spray pattern or replace the fuel injection nozzle.
114 SERIES
12-151
TESTING .UEL DRAIN PIPING BLEEDING AIR .ROM .UEL SYSTEM
TESTING .UEL DRAIN PIPING

The fuel system uses fuel to cool and lubricate the fuel injection pump and fuel injection nozzle. .uel is supplied continuously from the fuel injection pump, and a small amount of fuel leaks from the needle valve of the fuel injection nozzle during fuel injection. The fuel that leaks is returned to the fuel tank by the fuel drain manifold.
The resistance in the fuel drain manifold affects the fuel injection pump measurement control and the operation of the fuel injection nozzle. The resistance in the fuel drain manifold hinders the fuel injection and raises the pressure in the fuel injection pump case. If the reason for the fuel being cut off is not clear, check the resistance in the manifold drain line when the engine is started again after the machine has been rested. Caution: The resistance raises the fuel temperature and lowers the engine output.
BLEEDING AIR .ROM .UEL SYSTEM

Control of the passage of air is carried out by the fuel injection pump through the fuel drain manifold. The small amount of air that enters when the filter or fuel injection pump supply line is replaced is automatically bled when the fuel filter is replaced according to the explanation.
In the following cases, bleed the air manually. When the fuel filter is not filled with fuel before installing. When the fuel injection pump has been replaced. When the connection of the fuel injection pipe is loose or the fuel injection pipe has been replaced. When the engine is first started or the engine is started after it has not been used for a long time.
12-152
114 SERIES
BLEEDING AIR .ROM LOW-PRESSURE CIRCUIT AND .UEL .ILTER

Loosen the air bleed plug of the fuel filter.
Operate the hand priming pump until no more bubbles come out with the fuel from the air bleed plug in the fuel filter. Tighten the joint bolt. 3 .uel filter air bleed plug: 9 Nm {0.92 kgm}
BLEEDING AIR .ROM .UEL INJECTION PUMP

With the Nihon Denso EP-9 fuel injection pump, the air and fuel can be bled from the positions shown in the diagram. Loosen the vent screw, operate the priming lever of the fuel supply pump, and prime the fuel injection pump. Tighten the vent screw.
Caution: The engine must be set to the RUN position. The engine may start, so check all safety measures. Use the normal procedure to start the engine. Caution: When using the starting motor to bleed the air from the fuel system, do not continue to crank it for more than 30 seconds. After cranking for 30 seconds, wait for 2 minutes. When the starting motor is cranked, it is possible to bleed the air through the fuel drain manifold line.
114 SERIES
12-153
BLEEDING AIR .ROM HIGH-PRESSURE CIRCUIT

Caution: The pressure of the fuel in the high-pressure fuel circuit will pierce your skin, so there is danger that it may cause serious injury. Loosen the mounting nut of the fuel injection pipe of the fuel injection nozzle, then run the engine to bleed the air. After bleeding the air, tighten the fuel injection pipe mounting nut.
Caution: If fuel is spilled on the hot exhaust manifold, there is danger of fire, so do not bleed the air when the engine is hot. Run the engine and bleed the air from one cylinder at a time until the engine rotation becomes smooth.
12-154
114 SERIES
ADJUSTING TIMING O. .UEL INJECTION PUMP

On the fuel injection pump, there is a plastic timing pin and a spring inside the cap at the top of the side surface on the outside of the pump. This pin is used to determine the position so that the pump shaft is interconnected at the top dead center (TDC) of the No. 1 cylinder. After installing the pump, set the spring under the head of the timing pin and install the cap. (A) Spring (B) Shaft with lock applied (C) Shaft with lock released
Install the pump to a suitable support bracket. Remove the cap from the pump lock device. The cap is at the top of the side surface on the outside of the pump.
Remove the plastic timing pin and spring.
.irst, install the timing pin, then install the spring. Hint for maintenance: Use the cut part at the tip of the timing pin for reference to determine the correct position of the timing pin. The cut part at the tip of this timing pin must be parallel to the pump so that the timing pin can mesh with the cut part of the pump shaft.
114 SERIES
12-155
Install the nut to the pump shaft.
Push down in the spring and rotate the pump shaft clockwise so that the tip of the timing pin enters the cut part of the pump shaft. The key groove of the shaft will come to the two oclock position.
Caution: The timing pin may fit completely into the cut part of the pump at the point where it is first inserted. In this case, the pump is locked. When rotating the pump shaft, do not apply a torque of more than 7 Nm {0.7 kgm}. If the pump shaft will not rotate at a torque of 7 Nm {0.7 kgm}, remove the spring and timing pin, and rotate the pump slightly. Then repeat the previous step.
When rotating clockwise or in the opposite direction, apply a strong impact to the handle of the range to remove the nut from the pump drive shaft.
12-156
114 SERIES
Install the timing pin cover. 3 Timing pin cover: 70 Nm {0.7 kgm}
114 SERIES
12-157
TROUBLESHOOTING DE.ECTIVE OPERATION O. COOLING SYSTEM

TROUBLESHOOTING
The function of the cooling system is to maintain the engine at the specified operating temperature. The heat produced by the engine is partially absorbed by the cooling water circulating in the cylinder block and cylinder head. The heat absorbed by the cooling water is removed while the water flows inside the radiator. When carrying out troubleshooting for overheating, do not forget that if the level of the oil in the oil pan is too high, the friction caused when the connecting rod journal is immersed in the oil will generate more heat. .illing with oil above the specified level will increase the oil temperature, and this will increase the temperature of the cooling water passing through the oil cooler.
The cooling system is designed so that the specified amount of cooling water is used. If the water level is low, the engine will operate at a temperature higher than the specified temperature. Caution: If water must be added frequently, there is leakage in the cooling system. Locate the cause of the leakage and repair it.
Caution: The cooling water passages in the engine must be completely filled with cooling water. When the engine is running, air (bubbles) in the cooling water will cause corrosion due to cavitation, and this will reduce the efficiency of the heat transfer. If there are excessive bubbles, it will cause concentrated overheating at one part of the cylinder head and cylinder block, and this will cause cracking of the cylinder head, scoring of the cylinder, and blowing out from the head gasket.
12-158
114 SERIES
When adding water, always bleed the air from the cooling passage. The air is bled from the clearance at the jiggle pin, the hose of the top radiator, and the opening of the water filler. .or engines with aftercooler, open the head valve when adding water to further bleed the air. Caution: If water is added at a speed of 14 liters per minute, the air can be completely bled.
Caution: When adding cooling water, mix the water and antifreeze before adding it. Antifreeze does not have the same ability as water to remove heat from the engine, so if the antifreeze is added to the engine first, there will be overheating before the liquid is completely mixed. The ratio of antifreeze to water differs according to the minimum ambient temperature. Details are given in the Operation and Maintenance Manual, so refer to the manual when mixing the antifreeze and water. Never use coolant in which antifreeze exceeds a ratio of 60%. 1. Mix the water and antifreeze. 2. Stir the water and antifreeze. Caution: Never use water only as the coolant. If water only is used, there will be damage from corrosion. The small holes in the head gasket are particularly likely to become clogged. The holes are orifices and their size is important. Do not increase the size of the orifice. If the orifice is made larger, the flow of the cooling water will become poor and it will be impossible to prevent overheating. Water will cause rust, so the narrow cooling water passages will become even narrower. In addition, if water only is used as the coolant, rust will form on the cup plug in a comparatively short time, and this will cause leakage of water. Caution: If the cooling water is suddenly lost when the engine is under heavy load, it will cause serious damage to the piston and cylinder bore.
114 SERIES
12-159
RADIATOR CAP
The cooling system uses a pressure cap to prevent the cooling water from boiling. The following caps are specified for the recommended two systems. System A (for standard) B (for light load) 104C 99C Cap 103 kPa (1.06 kg/cm2) 48 kPa (0.49 kg/cm2)
An unsuitable or defective cap will cause the cooling water to flow out or the engine to operate at high temperature.
If air enters the cooling water, it will cause overheating or overflowing of the cooling water when the engine is hot. When the air is heated, it will expand and increase the pressure inside the system, and this may cause the cap to fly off. At the same time, compressed gas leaking from the head gasket will enter the cooling system and cause overflow.
Both the cooling and lubricating systems are under considerable pressure when the engine is running, so if there is any leakage from either system, it will mix with the fluid from the other system. .or example, the head gasket and oil cooler. (.or details, see COOLING SYSTEM.) Caution: The transmission oil also passes through the transmission oil cooler at the bottom of the radiator, and oil may leak into the cooling water system.
12-160
114 SERIES
WATER PUMP
The water pump sucks in cooling water from the bottom of the radiator and sends it to various parts of the engine. It then returns to the top of the radiator to be cooled. If the flow is reduced or blocked, the engine water temperature will rise.
The water pump is driven by a belt from the crankshaft pulley. An automatic belt tensioner is installed to prevent the belt from slipping of the pump pulley. If the tensioner does not work properly, the pump impeller speed will become slower and the flow of cooling water will be reduced.
The flow of cooling water to the water pump is also reduced by restriction of the hose. Normally, if the engine is running at low speed, there is no restriction of the hose. Check the hose when the engine is running at rated speed. Caution: Check that the engine is at the operating temperature.
If the water pump becomes worn or the operation is defective, the necessary amount of cooling water is not sent, so the cooling water temperature rises. Before checking the flow or replacing the water pump, use the troubleshooting procedure to investigate if there is any other possible cause.
114 SERIES
12-161
As explained in the section about the cooling water, resistance in the passage will hinder the flow of water.
RADIATOR, .AN, AND RADIATOR SHUTTER

The air sent to the radiator fins by the fan passes through the radiator and cools the cooling water. Dust and dirt (scraps of paper, dry leaves, pieces of material, etc.) on the jobsite will block the fins and hinder the flow of air, and this will reduce the cooling effect of the radiator.
If the fan is belt driven and the belt slips, the fan speed will become slower and this will reduce the cooling effect. Defective operation of the automatic belt tensioner is one problem. Caution: Check the fan hub and the bearings of the other pulleys to see if they are the cause of vibration or slippage of the belt.
If there is any problem in the electric circuit of the electric fan, the air flow will become insufficient, and this will lead to a rise in the temperature of the engine cooling water. Caution: Check that the temperature sensor is operating correctly.
12-162
114 SERIES
There are also cases where a heat detecting fan is used. This type of fan is actuated only when it is needed to maintain the cooling water at a constant temperature. If the fan does not rotate even when the cooling water temperature goes up, the engine will overheat. If the fan does not stop even when the water temperature goes down, the engine will operate at low temperature. Caution: Check that the temperature sensor is operating correctly.
The radiator shutter acts to control the amount of air passing through the radiator. If the radiator shutter is not opened when it is needed, the engine will overheat; if it is not closed, the air flow will be too high and the engine will overcool. Caution: Check that the air temperature sensor is operating correctly. Check the control of the air pressure actuated shutter. Check for leakage of air.
If the fan shroud is not suitable or is damaged, the air flow will be reduced and the engine will overheat. Caution: Check that the same air is not being circulated repeatedly. Check also that the baffle is not missing.
THERMOSTAT
The thermostat controls the temperature of the cooling water. If the water temperature goes below the operating temperature, the cooling water is sent through the bypass circuit to the water pump. When the water temperature goes up and reaches a certain temperature, the thermostat opens, closes the cooling water bypass circuit, and sends the cooling water to the radiator.
114 SERIES
12-163
Caution: Never run the engine with the thermostat not installed. If there is no thermostat, the cooling water will flow through the circuit with the least resistance and go to the water pump, so the engine will overheat.
If the thermostat is unsuitable or is not working properly, the engine will overheat or overcool.
As given in the section on the cooling water, be careful not to touch the cooling system. Use the jiggle pin when adding water to the cooling water system and bleed the air.
After bleeding the air and completing the addition of water, use the jiggle pin as a check valve to prevent the cooling water from flowing through the pin hole when the engine is running. Caution: If there is no jiggle pin, the engine will overcool.
12-164
114 SERIES
If the jiggle pin blocks the hole, the thermostat will react to the water temperature and open to control the flow of water to the radiator.
WATER TEMPERATURE GAUGE, EXCESSIVE .UEL, OVERLOAD

The gauge and sensors are used to measure the cooling water temperature. If these do not work properly, the temperature display will not be correct.
Caution: Excessive fuel will cause the engine to overheat. Check that the fuel injection pump is adjusted properly.
Caution: Normally, if the engine is overloaded, it will overheat.
114 SERIES
12-165
STANDARD VALUE TABLE FOR TESTING, ADJUSTING, AND TROUBLESHOOTING

Engine model Applicable machine model
Category Performance Item Engine speed Measurement conditions High idling speed Low idling speed 0C (without starting aid) 20 (with startig aid) At all speed At rated flywheel horsepower At rated flywheel horsepower All speed (20C) Quick acceleration (low idle high idle) Exhaust gas color At rated flywheel horsepower High idling speed Intake valve Valve clearance (When engine is hot or cold) Exhaust valve Engine proper Compression pressure Oil temperature: 40 60C (SAE30 or SAE15W-40) (engine speed: 250 rpm) mm mm MPa {kg/cm2} (rpm) Unit rpm rpm rpm rpm kPa {mmH2O} kPa {mmHg} kPa {mmHg} C
SAA6D114E-2 PC300-7, CD11OR-2

Standard value 2,180 50 900 25 Min. 130 Min. 100 Max. 3.72 {Max. 380} 120 160 {900 1,200} 135 173 {1,000 1,300} Max. 550 Max. 4.5 Bosch index Max. 1.5 Max. 1.0 0.30 0.56 Min. 2.4 {Min. 24.5} Max. 1.0 {Max. 100} 290 490 {3.0 5.0} 250 440 {2.5 4.5} Min. 120 {Min. 1.2} Min. 100 {Min. 1.0} 80 110 Max. 0.5 29.4 30.4 {300 310} 9.5 1 1,425 38 8 (Auto tension) Permissible value 2,180 50 900 25 Min. 100 Min. 100 7.50 {762} 93 {700} 107 {800} 600 6.5 2.5 2.0 2.0 {20.4} 2.0 {200} 210 {2.1} 180 {1.8} 80 {0.8} 70 {0.7} 120 1.0 23.5 {240} 9.5 1 1,425 38 6 10 (Auto tension)
WA380-5
Standard value 2,250 50 920 + 50 0 Min. 130 Min. 100 Max. 3.72 {Max. 380} 100 140 {750 1,050} 107 147 {800 1,100} Max. 550 Max. 4.5 Max. 1.5 Max. 1.0 0.30 0.56 Min. 2.4 {Min. 24.5} Max. 1.0 {Max. 100} 290 490 {3.0 5.0} 250 440 {2.5 4.5} Min. 120 {Min. 1.2} Min. 100 {Min. 1.0} 80 110 Max. 0.5 29.4 30.4 {300 310} 8.5 1 8 (Auto tension) Permissible value 2,250 50 920 + 50 0 Min. 100 Min. 100 7.50 {762} 73 {550} 80 {600} 600 6.5 2.5 2.0 2.0 {20.4} 2.0 {200} 210 {2.1} 180 {1.8} 80 {0.8} 70 {0.7} 120 1.0 23.5 {240} 8.5 1 6 10 (Auto tension)
Nessary stating speed Intake resistance Boost pressure
Intake, exhaust system
Exhaust pressure (turbine outlet pressure) Exhaust temperature (turbine inlet temp.)
At rated flywheel horsepower kPa Blow-by pressure (SAE30 or SAE15W-40) (water temp.: Min. 70C) {mmH2O} At rated flywheel horsepower SAE30 or SAE15W-40 oil kPa {kg/cm2} kPa {kg/cm2} kPa {kg/cm2} kPa {kg/cm2} C % MPa {kg/cm2} degree kPa {kg/cm2} rpm mm
Lubrication system
SAE10W oil Oil pressure (oil temperature: Min. 80C) At low idling SAE30 or SAE15W-40 oil SAE10W oil Oil temperature Oil consumption ratio All speed (Oil in oil pan) At continuous rated horsepower (Ratio for fuel consumption)
Fuel system
Fuel injection pressure Nozzle tester Fuel injection timing Radiator pressure valve Fan speed Belt tension (Between alternator and idler) B. T. D. C Opening pressure (Differential pressure) At rated engine speed Deflection when pushed with a force of 59 N {6 kg}
12-200
(3)
Cooling system
114 SERIES
SAA6D114E-2 GD655-3A,3C
Standard value 2,250 50 825 50 Min. 130 Min. 100 Max. 3.72 {Max. 380} 100 140 {750 1,050} 107 147 {800 1,100} Max. 550 Max. 4.5 Max. 1.5 Max. 1.0 0.30 0.56 Min. 2.4 {Min. 24.5} Max. 1.0 {Max. 100} 290 490 {3.0 5.0} 250 440 {2.5 4.5} Min. 120 {Min. 1.2} Min. 100 {Min. 1.0} 80 110 Max. 0.5 29.4 30.4 {300 310} 8.5 1 8 (Auto tension) Permissible value 2,250 50 825 50 Min. 100 Min. 100 7.50 {762} 73 {550} 80 {600} 600 6.5 2.5 2.0 2.0 {20.4} 2.0 {200} 210 {2.1} 180 {1.8} 80 {0.8} 70 {0.7} 120 1.0 23.5 {240} 8.5 1 6 10 (Auto tension)
GD675-3A,3C
Standard value 2,250 50 825 50 Min. 130 Min. 100 Max. 3.72 {Max. 380} 100 140 {750 1,050} 107 147 {800 1,100} Max. 550 Max. 4.5 Max. 1.5 Max. 1.0 0.30 0.56 Min. 2.4 {Min. 24.5} Max. 1.0 {Max. 100} 290 490 {3.0 5.0} 250 440 {2.5 4.5} Min. 120 {Min. 1.2} Min. 100 {Min. 1.0} 80 110 Max. 0.5 29.4 30.4 {300 310} 8.5 1 8 (Auto tension) Permissible value 2,250 50 825 50 Min. 100 Min. 100 7.50 {762} 73 {550} 80 {600} 600 6.5 2.5 2.0 2.0 {20.4} 2.0 {200} 210 {2.1} 180 {1.8} 80 {0.8} 70 {0.7} 120 1.0 23.5 {240} 8.5 1 6 10 (Auto tension) Standard value Permissible value
114 SERIES
12-201
(2)
TROUBLESHOOTING
TROUBLESHOOTING O. ENGINE (S MODE)

Method of using troubleshooting charts ................................................................................................... 12-302 S-1 Starting performance is poor (Starting always takes time) ............................................................. 12-306 S-2 Engine does not start (1) Engine does not turn ................................................................................................................ 12-307 (2) Engine turns but no exhaust smoke comes out (.uel is not being injected) ............................ 12-308 (3) Exhaust smoke comes out but engine does not start (.uel is being injected) ......................... 12-309 S-3 Engine does not pick up smoothly (.ollow-up is poor) .................................................................... 12-310 S-4 Engine stops during operations ...................................................................................................... 12-311 S-5 Engine does not rotate smoothly (Hunting) ..................................................................................... 12-312 S-6 Engine lacks output (or lacks power) .............................................................................................. 12-313 S-7 Exhaust smoke is black (Incomplete combustion) .......................................................................... 12-314 S-8 Oil consumption is excessive (or exhaust smoke is blue) ............................................................... 12-315 S-9 Oil becomes contaminated quickly ................................................................................................. 12-316 S-10 .uel consumption is excessive ....................................................................................................... 12-317 S-11 Oil is in cooling water, or water spurts back, or water level goes down .......................................... 12-318 S-12 Oil pressure caution lamp lights up (Drop in oil pressure) .............................................................. 12-319 S-13 Oil level rises (Water, fuel in oil) ...................................................................................................... 12-320 S-14 Water temperature becomes too high (Overheating) ...................................................................... 12-321 S-15 Abnormal noise is made ................................................................................................................. 12-322 S-16 Vibration is excessive ...................................................................................................................... 12-323
114 SERIES
12-301
TROUBLESHOOTING
METHOD O. USING TROUBLESHOOTING CHARTS

This troubleshooting chart is divided into three sections: questions, check items, and troubleshooting. The questions and check items are used to pinpoint high probability causes that can be located from the failure symptoms or simple inspection without using troubleshooting tools. Next, troubleshooting tools or direct inspection are used to check the high probability causes to make final confirmation. [Questions] Sections A + B in the chart on the right corresponds to the items where answers can be obtained from the user. The items in B are items that can be obtained from the user, depending on the user's level. [Check items] The serviceman carries out simple inspection to narrow down the causes. The items under C in the chart on the right correspond to this. The serviceman narrows down the causes from information A that hi has obtained from the user and the results of C that hi has obtained from his own inspection. [Troubleshooting] Troubleshooting is carried out in the order of probability, starting with the causes that have been marked as having the highest probability form information gained from [Questions] and [Check items].
(b) (2) (3)
Causes
Questions
(a) (b) (c) (d) (e)
Check items
Troubleshooting
i ii iii
12-302
114 SERIES
TROUBLESHOOTING
1 2
Confirm recent repair history Degree of use Operated for long period
Seiz
114 SERIES
ed t urbo Clog cha rger ged , int air c Wor erfe lean renc n pi er e ston e l e m Clog ent ring ged , cyl , i n s d Imp eize er li rope d in ner ject r inj ion Defe ecti noz on t ctiv zle imin e in ject g ion pum p (e xces sive
The basic method of using the troubleshooting chart is as follows. Items listed for [Questions] and [Check items] that have a relationship with the Cause items are marked with , and of these, causes that have a high probability are marked with . Check each of the [Questions] are [Check items] in turn, and marked the or in the chart for items where the problem appeared. The vertical column (Causes) that has the highest number of points is the most probable cause, so start troubleshooting for that item to make final confirmation of the cause. 1. .or [Confirm Section, ask repair history] in the [Questions] Section, ask the user, and mark the Cause column with to use as reference for locating the cause of the failure. However, do not use this when marking calculations to narrow down the causes. 2. Use the in the Cause column as reference for [Degree of use (Operated for long period)] in the [Questions] section as reference. As a rule, do not use it when calculating be included if necessary to determine the order for troubleshooting.
Causes
12-303
inje
ctio n
TROUBLESHOOTING
Example of troubleshooting when exhaust gas is black Let us assume that [Clogged air cleaner] is taken to be the cause of black exhaust gas. Three symptoms have causal relationship with this problem: [Exhaust gas slowly became black], [Power slowly became weaker], and [Dust indicator is red]. If we look from these three symptoms to find the causes, we fine that there is a relationship with five causes. Let us explain here the method of using this causal relationship to pinpoint the most probable cause.
S-7 Exhaust gas is black (incomplete combustion) General causes why exhaust gas is black Insufficient intake of air Improper condition of fuel injection Excessive injection of fuel
Causes
Seiz ed t urbo Clog cha rger ged , int air c Wor erfe lean renc n pi er e ston e lem Clog ent ring ged , cyl , sei inde Imp zed r rope inje r inj ctio Defe ecti n no on t ctiv zzle imin e in Imp ject g ion rope pum r va Cru p (e lve she xces clea d, c ranc sive logg Lea e inje ed m kag ctio e of uffle n) air b Defe r etw ctiv een e c onta turb Defe ct o och ctiv f va arge e in lve, ject r an ion valv d he pum e se ad at p (ra ck, p lung er s eize d)
Legend : Possible causes (judging from Questions and check items) : Most probable causes (judging from Questions and Check items) : Possible causes due to length of use (used for a long period) : Items to confirm the cause. Confirm recent repair history Degree of use Color of exhaust gas Operated for long period Suddenly became black Questions Gradually became black Blue under light load Engine oil must be added more frequently Power was lost Suddenly Gradually
Non-specified fuel has been used Noise of interference is heard from around turbocharger Dust indicator is red Blow-by gas is excessive Engine pickup is poor and combustion is irregular Check items Troubleshooting When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Match marks on fuel injection pump are out of alignment Seal on injection pump has come off Clanging sound is heard from around cylinder head Exhaust noise is abnormal Muffler is crushed Leakage of air between turbocharger and head, loose clamp When turbocharger is rotated by hand, it is found to be heavy When air cleaner is inspected directly, it is found to be clogged When compression pressure is measured, it is found to be low Speed of some cylinders does not change when operating on reduced cylinders When check is made using delivery method, injection timing is found to be incorrect Injection pump test shows that injection amount is incorrect When valve clearance is checked directly it is found to be outside standard value When muffler is removed, exhaust gas color returns to normal When control rack is pushed, it is found to be heavy or does not return Replace Replace Replace Replace Replace Remedy Replace Repair Adjust Adjust Adjust Clean
12-304
114 SERIES
TROUBLESHOOTING
Five causes Step 1 Clarify the relationship between the three symptoms in the [Questions] and [Check items] section and the five Causes items in the vertical column.
Three symptoms
Step 2 Add up the total of and marks where the horizontal lines for the three symptoms and the vertical columns for the causes intersect. (1) Clogged air cleaner element: (2) Air leakage between turbocharger and head: (3) Clogged, seized injection nozzle: (4) Defective contact of valve, valve seat: (5) Worn piston ring, cylinder:
Step 3 The calculation in Step 2 show that the closest relationship is with [Clogged air cleaner element]. Follow this column down to the troubleshooting area and carry out the troubleshooting item marked . The Remedy is given as [Clean], so carry out cleaning, and the exhaust gas color should return to normal.
114 SERIES
12-305
TROUBLESHOOTING
S-1
S-1
Starting performance is poor (Starting always takes time)
General causes why exhaust smoke comes out but engine takes time to start Defective electrical system Insufficient supply of fuel Insufficient intake of air Improper selection of fuel (At ambient temperature of 10C or below, ASTM D975 No. 2 diesel fuel is used) Battery charging rate
Ambient temperature 20C 0C 10C Charging rate 100 % 1.28 1.29 1.30 90 % 1.26 1.27 1.28 80 % 1.24 1.25 1.26 75 % 1.23 1.24 1.25 70 % 1.22 1.23 1.24
Causes
The specific gravity should exceed the value for the charging rate of 70% in the above table. In cold areas the specific gravity must exceed the value for the charging rate of 75% in the above table.
Confirm recent repair history Degree of use of machine Ease of starting Questions Indicator lamp does not light up Engine oil must be added more frequently Replacement of filters has not been carried out according to operation Manual Non-specified fuel has being used Dust indicator lamp is red Battery charge lamp is ON Starting motor cranks engine slowly When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Engine does not pick up smoothly, and combustion is irregular Check items Blow-by gas is excessive Timing lock on fuel injection pump does not match Mud is stuck to fuel tank cap When engine is cranked with starting motor, 1) Little fuel comes out even when injection pump piping sleeve nut is loosened 2) Little fuel comes out even when fuel filter air bleed plug is loosened Leakage from fuel piping There is hunting from engine (rotation is irregular) When compression pressure is measured, it is found to be low When air cleaner element is inspected directly, it is found to be clogged When fuel filter, strainer are inspected directly, they are found to be clogged Troubleshooting When feed pump strainer is inspected directly, it is found to be clogged Heater mount does not become warm Is voltage 2630V between alternator terminal B and terminal E with engine at low idling? Either specific gravity of electrolyte or voltage of battery is low Speed does not change when operation of certain cylinders is stopped When control rack is pushed, it is found to be heavy or does not return (check after removing fuel injection pump) When fuel tank cap is inspected directly, it is found to be clogged Replace Replace Replace Replace Replace Replace Replace Replace Replace Adjust Correct Correct Clean Clean Clean Clean Yes No Operated for long period Gradually became worse Starts when warm
Remedy
Use a test stand
12-306
n pi ston Defe ring , cyl ctive inde cont Clog r act o ged f val a ir cle ve, v Clog aner ged elem alve sea fuel t Clog ent filte ged r, st rain feed er Elec pum trica p ga l int uze ake Defe filte air h ctive r eate r e gula Defe r tor ctive alter Defe nato ctive r or d Defe eter ctive iora ted injec Defe batt tion tive ery nozz injec le Defe tion tive t i min injec g Leak tion age, pum clog p (rac Clog ging k, pl ged , air ung air b in fu er st Defe reat el pi uck) ctive her ping h o f e l e in ed p Defe fuel ump ctive t ank boo st co mpe nsat or c ance l
Wor
114 SERIES
TROUBLESHOOTING
S-2
S-2
Engine does not start

(1) Engine does not turn
Causes
General causes why engine does not turn 5 Seizure inside engine .or seizure inside the engine, carry out the troubleshooting for S-4 Engine stops during operation. .ailure in power train Defective electrical system
ctiv ew iring Defe ctiv of s e or tarti Defe dete ng c ctiv rior ircu e st ated it artin Bro batt ken gm ery r o i n t o g ge Defe r ar ctiv e sa fety Defe rela ctiv y or e ba Defe ttery safe ctiv ty s rela e ba witc y Defe ttery h ctiv t e r e fu min el cu al co Defe t so nne ctiv leno e st ctio artin n id g sw itch
Questions
Confirm recent repair history Degree of use of machine Operated for long period Condition of horn when Horn sounds starting switch is turned Horn volume is low ON Speed of rotation is low When starting switch is Makes grating noise turned to START, pinion Soon disengages pinion again moves out, but Makes rattling noise and does not turn When starting switch is turned to START, pinion does not move out When starting switch is turned to ON, there is no clicking sound
Troubleshooting of defective wiring in starting circuit
Check items
Battery terminal is loose When starting switch is turned ON, linkage is not actuated When battery is checked, battery electrolyte is found to be low Specific gravity of electrolyte, voltage of battery is low For the following conditions 1) - 5), turn the starting switch OFF, connect the cord, and carry out troubleshooting 1) When terminal B and terminal C of starting switch are connected, engine starts 2) When terminal B and terminal C of starting motor are connected, engine starts 3) When terminal B and terminal C of safety relay are connected, engine starts 4) When terminal of safety switch and terminal B of starting motor are connected, engine starts 5) There is no 24V between battery relay terminal b and terminal E When ring gear is inspected directly, tooth surface is found to be chipped Cannot be moved by hand even when linkage of fuel cut solenoid is disconnected Remedy
Troubleshooting
Defe
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
114 SERIES
12-307
TROUBLESHOOTING
S-2
(2) Engine turns but no exhaust smoke comes out (Fuel is not being injected)
General causes why engine turns but not exhaust smoke comes out Supply of fuel impossible Supply of fuel extremely small Improper selection of fuel (particularly in winter)
Type of fuel Selection of fuel according to ambient temperature
22 30 4 20 14 10 32 0 50 10 68 20 86 30 104F 40C
Causes
ken inje ctio Defe n pu ctiv mp e in driv ject Seiz ion e sh ed, pum aft, brok key p (ra en f Clog ck, p e ged ed p lung fuel ump Clog er s filte pist ged eize r, st on d) feed rain Insu e p r u ffici mp ent stra fuel Clog iner in ta ged , lea nk Clog king ged fuel air b pipi Defe reat ng ctiv her e fu hole Imp e l cu in fu rope t so el ta r fue leno nk l us i d ed
ASTM D975 No. 2

Diesel oil
ASTM D975A No. 1
If No. 3 diesel oil is not available in winter, it is also possible to mix No. 2 diesel oil 50:50 with kerosene.
Confirm recent repair history Questions Degree of use of machine Operated for long period Exhaust smoke suddenly stops coming out (when starting again) Replacement of filters has not been carried out according to Operation Manual Fuel tank is found to be empty There is leakage from fuel piping Mud is stuck to fuel tank cap When starting switch is turned ON, linkage is not actuated Check items When fuel filter is drained, fuel does not come out When engine is cranked with starting motor, 1) No fuel comes out even when fuel filter air bleed plug is loosened 2) No fuel spurts out even when injection pump piping sleeve nut is loosened Rust and water are found when fuel tank is drained Inspect injection pump directly When control rack is pushed, it is found to be heavy, or does not return Inspect feed pump directly When fuel filter, strainer are inspected directly, they are found to be clogged When feed pump strainer is inspected directly, it is found to be clogged When fuel cap is inspected directly, it is found to be clogged Cannot be moved by hand even when linkage of fuel cut solenoid is disconnected Replace Replace Replace Replace Replace Replace Replace Replace Replace Remedy Replace Troubleshooting
12-308
1
Bro
114 SERIES
TROUBLESHOOTING
S-2
(3) Exhaust smoke comes out but engine does not start (.uel is being injected)
General causes why exhaust smoke comes out but engine not start Lack of rotating force due to defective electrical system Insufficient supply of fuel Insufficient intake of air Improper selection of fuel and oil
Causes
ctive , bro Defe ken valv ctiv e sys e in j tem Wor ecti (valv on p n pi e, ro ston ump cker Clog ring (rac leve k, p ged , cyl r, etc lung i f n uel d Clog .) e er s r filte l i n ged tuck e r, st r f ) eed rain Clog er pum ged p st air c rain Defe l e er a ner ctiv e el elem ectr Defe e nt ical ctiv inta e or ke a Lea d e terio i r he kag e, cl rate ater ogg d ba Clog ing, ttery ged a i i r in njec Clog fuel tion ged syst noz air b em zle, Imp defe reat rope h ctiv e r fue r ho e spra le in l us y ed fuel tank cap
Confirm recent repair history Degree of use of machine Operated for long period Questions Suddenly failed to start When engine is cranked, abnormal noise is heard from around cylinder head Engine oil must be added more frequently Non-specified fuel is being used Replacement of filters has not been carried out according to Operation Manual Rust and water are found when fuel tank is drained Dust indicator lamp is red Indicator lamp does not light up Starting motor cranks engine slowly Mud is stuck to fuel tank cap When fuel lever is placed at FULL position, it does not contact stopper Check items When engine is cranked with starting motor, 1) Little fuel comes out even when injection pump piping sleeve nut is loosened 2) No fuel comes out even when fuel filter air bleed plug is loosened There is leakage from fuel piping When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low When fuel filter is drained, no fuel comes out Remove head cover and check directly When control rack is pushed, it is found to be heavy, or does not return When compression pressure is measured, it is found to be low When fuel filter, strainer are inspected directly, they are found to be clogged When feed pump strainer is inspected directly, it is found to be clogged When air cleaner element is inspected directly, it is found to be clogged Heater mount does not become warm Either specific gravity of electrolyte or voltage of battery is low When feed pump is operated, there is no response, or operation is too heavy Speed does not change when operation of certain cylinders is stopped When fuel tank cap is inspected directly, it is found to be clogged Replace Replace Replace Replace Correct Correct Clean Clean Clean Clean Remedy Clean
Troubleshooting
Defe
114 SERIES
12-309
TROUBLESHOOTING
S-3
S-3
Engine does not pick up smoothly (.ollow-up is poor)

Causes
General causes why engine does not pick up smoothly Insufficient intake of air Insufficient supply of fuel Improper condition of fuel injection Improper fuel used
Confirm recent repair history Degree of use of machine Operated for long period Replacement of filters has not been carried out according to Operation Manual Non-specified fuel is being used Engine oil must be added more frequently Engine pick-up suddenly became poor Rust and water are found when fuel tank is drained Dust indicator lamp is red Noise of interference is heard from around turbocharger Color of exhaust gas Blue under light load Black
Questions
Clanging sound is heard from around cylinder head Check items Mud is stuck to fuel tank cap There is leakage from fuel piping High idling speed under no load is normal, but speed suddenly drops when load is applied There is hunting from engine (rotation is irregular) When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Blow-by gas is excessive When air cleaner element is inspected directly, it is found to be clogged When fuel filter, strainer are inspected directly, they are found to be clogged When feed pump strainer is inspected directly, it is found to be clogged Speed does not change when operation of certain cylinders is stopped When control rack is pushed, it is found to be heavy, or does not return When compression pressure is measured, it is found to be low When turbocharger is rotated by hand, it is found to be heavy When valve clearance is checked directly, it is found to be outside standard value When fuel tank cap is inspected directly, it is found to be clogged When feed pump is operated, operation is too light or too heavy Replace Replace Replace Remedy Replace Correct Correct Adjust Clean Clean Clean Clean
12-310
Troubleshooting
ged air c Clog lean ged er e lem f uel Clog ent filte ged r, st f r eed aine Clog pum r ged p st inje rain Seiz ctio er ed i n noz njec zle, tion Wor d efec pum n pi tive p pl ston spra Seiz u n r i ger ng, y ed t cylin urbo d Imp e c harg r lin rope er er, i r va nter Clog lve fere clea ged nce r air b anc e Clog reat her ged hole , lea Defe king in fu ctiv fuel el ta e co nk c pipi ntac ng ap t of valv e an d va lve seat
Clog
114 SERIES
TROUBLESHOOTING
S-4
S-4
5
Engine stops during operations

Causes
ken , sei zed Bro pist ken on, , sei con zed Brok nec cran en d ting ksha ynam rod ft be Bro i c valv ken a ring e sy , sei stem Bro zed ken gea (valv pum r tra e, r o in p au Bro cker ken x leve iliar fuel r , et y eq Insu pum c.) ui pm ffici p dr e ent nt i v e f Clog uel sha in ta ft, k ged ey nk fuel Clog f i l ter, ged stra f e iner ed p Bro ump ken , sei stra zed Clog iner feed ged , lea pum king Clog p pi ston fuel ged pipi air b Defe ng r eath ctiv er h e in ole ject Fail in fu ion ure el ta pum in p nk owe p ( ra r t ra ck, p in lung er s tuck )
General causes why engine stops during operations Seized parts inside engine Insufficient supply of fuel Overheating If the is overheating and the engine stops, carry out troubleshooting for overheating. (See S-14 Water temperature becomes too high) .ailure in power train 5 If the engine stops because of a failure in the power train, carry out troubleshooting for the chassis.
Confirm recent repair history Degree of use of machine Operated for long period Abnormal noise was heard and engine stopped suddenly Condition when engine Engine overheated and stopped stopped Engine stopped slowly There was hunting and engine stopped Replacement of filters has not been carried out according to Operation Manual Non-specified fuel is being used Fuel level lamp lights up Fuel tank is found to be empty When feed pump is operated, operation is too light or too heavy Mud is stuck to fuel tank cap Check items Engine rotates, but stops when power train is operated Does not turn at all When it is attempted to turn by hand using barring tool Turns in opposite direction Moves amount of backlash Shaft does not turn Metal particles are found when oil is drained Remove oil pan and inspect directly Remove head cover and inspect directly Troubleshooting When gear train is inspected, it does not turn Rotates when pump auxiliary equipment is removed When fuel filter, strainer are inspected directly, they are found to be clogged When feed pump strainer is inspected directly, it is found to be clogged Inspect feed pump directly When control rack is pushed, it is found to be heavy, or does not return Replace Replace Replace Replace Replace Replace Replace Remedy Replace Correct Clean Clean Clean Troubleshooting of chassis Add Rust and water are found when fuel tank is drained
Questions
Bro
114 SERIES
12-311
TROUBLESHOOTING
S-5
S-5
Engine does not rotate smoothly (Hunting)

Causes
ctiv e op Defe erat ctiv ion e ad of g Defe ove just rnor men ctiv e op t of gov Low erat erno ion idlin of c r g sp Insu ontr e e ffici ol ra d is ent t c o k o fuel Clog in ta low ged n f k e ed p Clog ump ged stra fuel Clog iner filte ged, r, st air in rain Clog er circu ged, it be air in tw ee Clog c n fu i rcuit ged el ta betw air b nk a een nd f reat feed eed her pum pum hole p p an in fu d no el ta zzle nk
General causes why engine does not rotate smoothly 5 Air in fuel system Defective governor mechanism Defective electric governor mechanism (engine with electric governor) If hunting stops when electric governor rod is disconnected, carry out troubleshooting for the troubleshooting for electric system.
Confirm recent repair history Degree of use of machine Operated for long period Questions Occurs at a certain speed range Condition of hunting Occurs at low idling Occurs even when speed is raised Occurs on slopes Replacement of filters has not been carried out according to Operation Manual Fuel tank is found to be empty Rust, water are found when fuel tank is drained Leakage from fuel piping Check items When feed pump is operated, 1) No response, light, return is quick 2) No response, light, return is normal Engine speed sometimes rises too far Engine is sometimes difficult to stop Seal on injection pump has come off When governor lever is moved it is found to be stiff When injection pump is tested, governor is found to be improperly adjusted When control rack is pushed, it is found to be heavy, or does not return When fuel tank cap is inspected directly, it is found to be clogged When feed pump strainer is inspected directly, it is found to be clogged When fuel filter, strainer are inspected directly, they are found to be clogged Correct Correct Adjust Adjust Adjust Adjust Clean Clean Remedy Clean Troubleshooting
Defe
12-312
Add
114 SERIES
TROUBLESHOOTING
S-6
S-6
Engine lacks output (or lacks power)

Insufficient intake of air Insufficient supply of fuel Improper condition of fuel injection Improper fuel used (if non-specified fuel is used, output drops) Lack of output due to overtaking 5 If there is overheating and lack of output, carry out troubleshooting for S-14 overheating.
Causes
Clog
Confirm recent repair history Degree of use of machine Operated for long period Power was lost Questions Suddenly Gradually
Engine oil must be added more frequently Replacement of filters has not been carried out according to Operation Manual Non-specified fuel is being used Dust indicator lamp is red Color of exhaust gas Black Blue under light load
Noise of interference is heard from around turbocharger Blow-by gas is excessive Engine pickup is poor and combustion is irregular Check items High idling speed under no load is normal, but speed suddenly drops when load is applied When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low There is hunting from engine (rotation is irregular) Clanging sound is heard from around cylinder head High idling speed of engine is low Leakage from fuel piping When air cleaner element is inspected directly, it is found to be clogged When turbocharger is rotated by hand, it is found to be heavy When compression pressure is measured, it is found to be low When fuel filter, strainer are inspected directly, they are found to be clogged When feed pump strainer is inspected directly, it is found to be clogged Speed does not change when operation of certain cylinders is stopped When control rack is pushed, it is found to be heavy, or does not return When valve clearance is checked directly, it is found to be outside standard value When lever is placed at FULL position, it does not contact stopper When feed pump is operated, operation is too light or too heavy When fuel tank cap is inspected directly, it is found to be clogged Replace Replace Replace Replace Replace Remedy Replace Correct Correct Adjust Adjust Clean Clean Clean Clean Troubleshooting
114 SERIES
ged air c lean ed t er e urbo lem Wor cha ent rger n pi , int ston erfe Clog ring renc ged , cyl e i nde fuel Clog r f i l t ged er, s feed tr Clog pum ainer ged p st i n rain ject Seiz er i on ed i noz njec z le, d Imp tion efec rope pum tive r va p pl spra Defe lve ung clea y ctiv er ranc e co e n Ben t a c t fue t of valv l lev Clog e an er li ged nka d va ge, , lea lve defe king seat Clog ctiv fuel ged e adju p air b ipin Defe stm reat g ent ctiv her e bo hole Defe ost i n ctiv com fuel ew pen tank estg sat ate diap or diap hrag hrag m m
Seiz
General causes why engine lacks output
12-313
TROUBLESHOOTING
S-7
S-7
Exhaust smoke is black (Incomplete combustion)

Causes
ed t urbo Clog cha rger ged , int air c Wor erfe lean renc n pi er e ston e lem Clog ent ring ged , cyl i nde inje Imp ctio r lin rope n no er r inj z zle, Defe ecti defe on t ctiv ctiv imin e in e sp Imp ject g ray ion rope p r u valv mp Cru (exc e cle she essi aran d, c ve i logg ce Lea njec ed m kag tion e of uffle ) a Defe r ir be ctiv t w een e c onta turb Defe ct o och ctiv f va arge e in lve ject r an and ion d he pum valv ad e se p ( ra at ck, p lung er s eize d)
General causes why exhaust smoke is black Insufficient intake of air Improper condition of fuel injection Excessive injection of fuel
Confirm recent repair history Degree of use of machine Operated for long period Suddenly became black Questions Color of exhaust gas Gradually became black Blue under light load Engine oil must be added more frequently Power was lost Suddenly Gradually
Non-specified fuel is being used Noise of interference is heard from around turbocharger Dust indicator lamp is red Blow-by gas is excessive Engine pickup is poor and combustion is irregular Check items When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Timing lock on fuel injection pump does not match Seal on injection pump has come off Clanging sound is heard from around cylinder head Exhaust noise is abnormal Muffler is crushed Leakage of air between turbocharger and head, loose clamp When turbocharger is rotated by hand, it is found to be heavy When air cleaner element is inspected directly, it is found to be clogged When compression pressure is measured, it is found to be low Troubleshooting Speed does not change when operation of certain cylinders is stopped When check is made using delivery method, injection timing is found to be incorrect Injection pump test shows that injection amount is incorrect When valve clearance is checked directly it is found to be outside standard value When muffler is removed, exhaust color returns to normal When control rack is pushed, it is found to be heavy, or does not return Replace Replace Replace Replace Replace Correct Adjust Adjust Adjust Clean Remedy Replace
12-314
Seiz
114 SERIES
TROUBLESHOOTING
S-8
S-8
5
Oil consumption is excessive (or exhaust smoke is blue)

Do not run the engine at idling for more than 20 minutes continuously. (Both low and high idling)
Causes
ken pist on r Wor ing n pi ston Clog ring ged , cyl inde brea Lea r lin ther kag er or b e fro reat Lea mo her kag il fil hos e fro ter o e mo Lea r oi l il pi kag c o pi ng e fro oler Lea mo kag il dr e fro ain pl ug mo Bro ken il pa oil c n or oole Wor cylin r n se der al a hea t tur Wor d bine n se a e l n at b d Wor low n, b er e roke nd n re Dus Turb ar s t su eal, cked och seal arge Wor in fr s r n va urfa om inta ce lve (ste k e syst m, g em uide ), br oke n se al
General causes why oil consumption is excessive Abnormal combustion of oil External leakage of oil Wear of lubrication system
Confirm recent repair history Degree of use of machine Operated for long period Oil consumption suddenly increased Questions Engine oil must be added more frequently Engine oil becomes contaminated quickly Exhaust smoke is blue under light load Amount of blow-by gas Excessive None Area around engine is dirty with oil There is oil in engine cooling water Check items When exhaust pipe is removed, inside is found to be dirty with oil When turbocharger air supply pipe is removed, inside is found to be dirty with oil Oil level in clutch or TORQFLOW transmission damper chamber rises Clamps for intake system are loose When compression pressure is measured, it is found to be low Troubleshooting When breather element is inspected, it is found to be clogged with dirty oil There is external leakage of oil from engine Pressure-tightness test of oil cooler shows there is leakage Excessive play of turbocharger shaft Inspect rear seal directly When intake manifold is removed, dust is found inside When intake manifold is removed, inside is found to be dirty with oil Replace Replace Replace Replace Replace Correct Correct Correct Correct Correct Correct Remedy Correct Clean
Bro
114 SERIES
12-315
TROUBLESHOOTING
S-9
S-9

Oil becomes contaminated quickly

Causes
General causes why oil becomes contaminated quickly Entry of exhaust gas due to internal wear Clogging of lubrication passage Improper fuel Improper oil used Operation under excessive load
Confirm recent repair history Questions Degree of use of machine Operated for long period Engine oil must be added more frequently Non-specified oil is being used Color of exhaust gas Blue under light load Black Excessive Check items Amount of blow-by gas None When oil filter is inspected, metal particles are found When exhaust pipe is removed, inside is found to be dirty with oil Engine oil temperature rises quickly When compression pressure is measured, it is found to be low Troubleshooting When breather element is inspected directly, hose is broken or is found to be clogged with dirty oil When oil filter is inspected directly, it is found to be clogged When oil cooler is inspected directly, it is found to be clogged Turbocharger oil drain tube is clogged Excessive play of turbocharger shaft When safety valve is directly inspected, spring is found to be catching or broken Replace Replace Replace Remedy Replace Clean Clean Clean
Carry out troubleshooting for S-7 Exhaust smoke is black.
Wor
12-316
n pi ston Clog ring , cyl ged inde brea Clog r lin ther ged er , bre o athe il fil Wor r t e h r o n va se lve, Clog valv ged e g ui de oil c Clog o ol e ged r t u rboc Defe harg ctiv e se er o Exh al a i l dr aus t tur ain t sm tube boc harg oke is b er tu lack rbin e
end
114 SERIES
TROUBLESHOOTING
S-10
S-10 .uel consumption is excessive

General causes why fuel consumption is excessive Leakage of fuel Improper condition of fuel injection Excessive injection of fuel
Defe ctive injec tion Defe pum ctive p (ex nozz Defe cess le ho ive i ctive lder njec spra injec tion Defe y t i o ) n ctive pum fuel p plu Exte injec n g er rnal tion leak timi age ng Leak from age fuel of fu pipin el in Defe side g, fu ctive el fil h oil s ead ter Defe eal i cove ctive nsid r e adju f e e d pu stme mp nt o (pist f fue on) l con trol linka ge
Causes
Confirm recent repair history Questions Degree of use of machine Operated for long period
Condition of fuel consumption More than for other machines of same model Gradually increased Suddenly increased Black Exhaust smoke color White
Seal on injection pump has come off There is irregular combustion
Check items Troubleshooting
When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Match mark on injection pump is misaligned There is external leakage of fuel from engine Engine oil level rises and smells of diesel fuel Engine low idling and high idling speeds are high Injection pump measurement shows that injection amount is excessive Speed does not change when operation of certain cylinders is stopped When control rack is pushed, it is found to be heavy, or does not return When check is made using delivery method, injection timing is found to be incorrect Remove head cover and inspect directly Remove feed pump and inspect directly When engine speed is measured, low idling and high idling speeds are found to be high
Replace
Replace
Correct
Correct
Correct
Adjust
Adjust
Remedy
Adjust
114 SERIES
12-317
TROUBLESHOOTING
S-11
S-11 Oil is in cooling water, or water spurts back, or water level goes down
General causes why oil in cooling water Internal leakage in lubrication system Internal leakage in cooling system
Causes
Confirm recent repair history Questions Degree of use of machine Operated for long period
Oil level Suddenly increased Gradually increased Hard water is being used as cooling water Engine oil level has risen, oil is cloudy white
Check items
Excessive air bubbles inside radiator, spurts back Hydraulic oil, transmission oil is cloudy white When hydraulic oil, transmission oil is drained, water is found Pressure-tightness test of oil cooler shows there is leakage Pressure-tightness test of cylinder head shows there is leakage Remove oil pan and inspect directly
Troubleshooting
Replace
Replace
Replace
Replace
Remedy
12-318
Replace
Brok en o il co oler Brok core en c , O-r ylind ing er h Brok ead, en p head owe r tra Hole gask in oi s ca et l coo used ler by p Inter ittin nal c g rack s in cylin der bloc k
114 SERIES
TROUBLESHOOTING
S-12
S-12 Oil pressure caution lamp lights up (Drop in oil pressure)

General causes why oil pressure lamp lights up 5 Leakage, clogging, wear of lubricating system Defective oil pressure control Improper oil used (improper viscosity) Deterioration of oil due to overheating Standards for engine oil selection
Type of oil
`!
Selection of SAE No. according to ambient temperature

` ` ! "+
Causes
SAE30CD
ged oil f ilter n be arin Clog g, jo urna ged stra l Clog iner ged insi de o oil p Bro il pa ipe ken insi n suct d e oi i Defe on p l pa ipe ctiv n e oi braz Lack l pu ing mp of o i l in o Defe il pa ctiv n e re gula Defe tor v ctiv e re alve lief Lea valv king e , cru Defe she d hy ctiv e oi drau l pre Defe lic p ssur ctiv ipin e oi e se g l n l sor eve Wat l sen er, f sor uel in o il
Wor
Engine oil
SAE10WCD SAE10W-30CD SAE15W-40CD
Confirm recent repair history Questions Degree of use of machine Operated for long period Replacement of filters has not been carried out according to Operation Manual Non-specified oil is being used Caution lamp lights up Lights up at low idling Condition when oil pressure lamp lights up Lights up at low, high idling Lights up on slopes Sometimes lights up Check items There is crushing, leakage from hydraulic piping (external) Oil level sensor lamp lights up When oil level in oil pan is inspected, it is found to be low Metal particles are found when oil is drained Metal particles are stuck to oil filter element Oil is cloudy white or smells of diesel oil When oil filter is inspected, it is found to be clogged Troubleshooting Remove oil pan and inspect directly Oil pump rotation is heavy, there is play There is catching of relief valve or regulator valve, spring or valve guide is broken When oil level sensor is replaced, oil level sensor lamp goes out When oil pressure is measured, it is found to be within standard value Replace Replace Remedy Replace Correct Correct Adjust Adjust Clean Clean Clean Clean
Carry out troubleshooting for S-13 Oil level rises.
Clog
Add
114 SERIES
12-319
TROUBLESHOOTING
S-13
S-13 Oil level rises (Water, fuel in oil)

5 If there is oil in the cooling water, carry out troubleshooting for S-11 Oil is in cooling water, or water level goes down.
Causes
ken oil c oole Defe r co ctiv re, O e no Bro -ring zzle ken hold cylin e r Wor s der leev n, d hea e ama d, h ead Defe ged gas rear ctiv ket e pu seal Lea mp surf kag aux ace e of i l i ary fuel Defe equ from ctiv i pm e pa pi pi ent Defe rt in n seal g in ctiv side side e th i n hea j e e Hole rmo ctio d co n pu sm stat ver ade mp Crac by p ks in ittin g side cylin der bloc k
General causes why oil level rises Water in oil (milky white) .uel in oil (diluted, and smells of diesel fuel) Entry of oil from other component
Confirm recent repair history Questions Degree of use of machine Operated for long period There is oil in radiator cooling water Fuel must be added more frequently Exhaust smoke is white When engine is first started, drops of water come from muffler Leave radiator cap open. When engine is run at idling, an abnormal number of bubbles appear, or water spurts back Oil level goes down in clutch, TORQFLOW transmission, or damper chamber Oil level goes down in hydraulic tank Engine oil smells of diesel fuel Water temperature is low Pressure-tightness test of oil cooler shows there is leakage Pressure-tightness test of cylinder head shows there is leakage Troubleshooting When compression pressure is measured, it is found to be low Inspect rear seal directly When pump auxiliary equipment is removed, seal is found to be damaged Remove head cover and inspect directly Remove injection pump and inspect directly Defective contact with thermostat seal valve Remove oil pan and check directly Replace Replace Replace Replace Replace Replace Remedy Replace Correct Correct Correct
12-320
Check items
Bro
114 SERIES
TROUBLESHOOTING
S-14
S-14 Water temperature becomes too high (Overheating)

General causes why water temperature becomes too high 5 Lack of cooling air (deformation, damage of fan) Drop in heat dissipation efficiency Defective cooling circulation system Rise in oil temperature in power train Carry out troubleshooting for chassis.
Causes
Confirm recent repair history Degree of use of machine Operated for long period Questions Condition of overheating Water temperature gauge Suddenly overheated Always tends to overheat Rises quickly Does not go down from red range
Radiator water level sensor lights up Fan belt whines under sudden load Cloudy white oil is floating on cooling water Cooling water flows out from overflow hose Excessive air bubbles inside radiator, water spurts back Check items Engine oil level has risen, oil is cloudy white There is play when fan pulley is rotated Radiator shroud, inside of underguard are clogged with dirt or mud When light bulb is held behind radiator, no light passes through Water is leaking because of cracks in hose or loose clamps When belt tension is inspected, it is found to be loose Power train oil temperature enters red range faster than engine water temperature
Carry out troubleshooting for chassis.
Troubleshooting
Temperature difference between top and bottom radiator tanks is excessive Temperature difference between top and bottom radiator tanks is slight When water filler port is inspected, core is found to be clogged When function test is carried out on thermostat, it does not open even at cracking temperature When water temperature is measured, it is found to be normal When oil cooler is inspected directly, it is found to be clogged When measurement is made with radiator cap tester, set pressure is found to be low When compression pressure is measured, it is found to be low Remove oil pan and inspect directly Replace Replace Replace Replace Replace Replace Replace Correct Correct Correct Remedy
Add
114 SERIES
Bro ken wat er p Clog ump ged , cru Clog she d ra ged diat radi or fi Defe ator ns ctiv core e ther Defe mos ctiv tat ( ew doe ater Lack s no tem of c t op pera ooli en) Fan t n u g re g wat belt aug er s l e i p Clog ping ged , wo , bro rn fa Defe ken n pu ctiv oil c lley e pr ool e essu Bro r ken re v cylin alve Hole der sm hea ade d, h ead Rise by p gas ittin in to ket g rque con vert er o il te mpe ratu re
12-321
TROUBLESHOOTING
S-15
S-15 Abnormal noise is made

5
ssive wea Seiz r of ed t pisto urbo n rin Mis c g, cy harg sing linde er, i , sei r line nter zed Clog r f e r b enc ged ush e , sei i ng Defe z e d ctiv i nj e e in ctio ject Defe nn i on ctiv pum oz z l e e in p (ra Defo ject i on ck, p rme pum d fa l ung Defe p (e n, fa er s x ctiv n cess eize belt e ad d) ive inte Brok just i n ject r f m en d eren e i on) n ynam t of c e valv Imp ic va rope e cle lve s r ge aran yste Leak a m (v ce r train age alve of ai b , a rock ckla r bet Defe er le sh wee ct in ver, n tur side etc.) boch muf arge fler ( r and divid ing b cylin oard der h out o ead f pos ition )
Judge if the noise is an internal noise or an external noise.
Causes
General causes why abnormal noise is made Abnormality due to defective parts Abnormal combustion Air sucked in from intake system
Confirm recent repair history Questions Degree of use of machine Operated for long period Condition of abnormal noise Gradually occurred Suddenly occurred
Non-specified fuel is being used Engine oil must be added more frequently Color of exhaust gas Blue under light load Black Metal particles are found in oil filter Blow-by gas is excessive Noise of interference is heard from around turbocharger Engine pickup is poor and combustion is abnormal
Check items
When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Seal on injection pump has come off Abnormal noise is loud when accelerating engine Clanging sound is heard from around cylinder head Leakage of air between turbocharger and cylinder head, loose clamp Vibrating noise is heard from around muffler When compression pressure is measured, it is found to be low When turbocharger is rotated by hand, it is found to be heavy Remove gear cover and inspect directly
Troubleshooting
Speed does not change when operation of certain cylinders is stopped When control rack is pushed, it is found to be heavy, or does not return Injection pump test shows that injection amount is incorrect Fan is deformed, belt is loose When valve clearance is checked, it is found to be outside standard value Remove cylinder head cover and inspect directly When muffler is removed, abnormal noise disappears Replace Replace Replace Replace Replace Replace Replace Replace Remedy Replace Correct Correct Correct
12-322
Exce
114 SERIES
TROUBLESHOOTING
S-16
S-16 Vibration is excessive

5
Wor n co nne ctin Wor g ro n ca d, m m b Loo ain u s h bea se e ing ring ngin Bro e m ken o u ntin part g bo Cen insi lts, de o ter o brok utpu f en en c Imp g i ne t sh ush rope aft ( and i on dam r pow gea Defe per) r tra er tr ctive i a n i n d bac ynam mis Defe klas alig ic va h ctiv ned lve s e in y s t ject e m ( i on valve pum , roc ker le p (e xces ver, etc. s sive tuck) fuel i nj e ctio n)
If there is abnormal noise together with the vibration, carry out troubleshooting also for S-15 Abnormal noise is made.
Causes
General causes why vibration is excessive Defective parts (abnormal wear, breakage) Improper alignment Abnormal combustion
Confirm recent repair history Questions Degree of use of machine Operated for long period Condition of vibration Suddenly increased Gradually increased Non-specified oil is being used Metal particles are found in oil filter Metal particles are found when oil is drained Oil pressure is low at low idling Check items Troubleshooting Vibration occurs at mid-range speed Vibration follows engine speed Exhaust smoke is black Seal on injection pump has come off Remove oil pan and inspect directly Remove side cover and inspect directly Inspect directly for loose engine mounting bolts, broken cushion Inspect inside of output shaft (damper) directly When face runout and radial runout are inspected, they are found to be incorrect Remove front cover and inspect directly Remove head cover and inspect directly Injection pump test shows that injection amount is incorrect Replace Replace Replace Replace Replace Correct Correct Remedy Adjust
114 SERIES
12-323
13 DISASSEMBLY AND ASSEMBLY

SPECIAL TOOL LIST .................................... SPECIAL TOOLS FOR DISASSEMBLY AND ASSEMBLY............................. OUTLINE OF DISASSEMBLY AND ASSEMBLY OF ENGINE ............... OUTLINE ................................................ OVERALL DISASSEMBLY OF ENGINE ....... ENGINE LIFTING TOOL AND BRACKET ............................... PREPARATION FOR STEAM CLEANING OF ENGINE .... STEAM CLEANING OF ENGINE ........... DRAINING OIL........................................ DRAINING COOLANT ............................ REMOVAL OF OIL FILTER..................... REMOVAL OF FUEL FILTER................. REMOVAL OF FUEL SUPPLY PIPE (LOW-PRESSURE SIDE)................ REMOVAL OF FUEL FEED PUMP ........ REMOVAL OF FUEL SUPPLY PIPE (HIGH-PRESSURE SIDE) ............... REMOVAL OF FUEL INJECTION PUMP FUEL SUPPLY PIPES ..................... REMOVAL OF BOOST COMPENSATOR TUBE .................. REMOVAL OF TACHOMETER DRIVE... REMOVAL OF FUEL INJECTION PUMP ................ REMOVAL OF AIR CONDITIONER COMPRESSOR..... INSTALLATION OF ENGINE TO ENGINE STAND ........................ REMOVAL OF TURBOCHARGER EXHAUST OUTLET CONNECTOR .................. REMOVAL OF WESTGATE ACTUATOR HOSE .......................... REMOVAL OF CYLINDER BLOCK BREATHER TUBE........................... REMOVAL OF CROSSOVER TUBE ...... REMOVAL OF INTAKE MANIFOLD COVER ........................ 13- 4 13- 4 13- 8 13- 8 13- 9 13- 9 13- 9 13- 9 13- 10 13- 10 13- 10 13- 11 13- 11 13- 11 13- 12 13- 12 13- 12 13- 13 13- 13 13- 14 13- 15 13- 16 13- 16 13- 16 13- 17 13- 17 REMOVAL OF AFTERCOOLER ............. REMOVAL OF FUEL DRAIN MANIFOLD ................ REMOVAL OF INJECTOR ...................... REMOVAL OF CYLINDER HEAD COVER .............. REMOVAL OF ROCKER LEVER............ REMOVAL OF PUSH ROD ..................... REMOVAL OF TURBOCHARGER OIL SUPPLY HOSE ......................... REMOVAL OF TURBOCHARGER OIL DRAIN TUBE............................. REMOVAL OF TURBOCHARGER.......... REMOVAL OF EXHAUST MANIFOLD.... REMOVAL OF DRIVE BELT ................... REMOVAL OF BELT TENSIONER ......... REMOVAL OF BELT TENSIONER BRACKET......... REMOVAL OF ALTERNATOR BRACKET................ REMOVAL OF ALTERNATOR................. REMOVAL OF ALTERNATOR BRACKET................ REMOVAL OF COOLANT OUTLET CONNECTOR ................... REMOVAL OF COOLANT AIR BLEED TUBE.......... REMOVAL OF COOLANT AIR BLEED VALVE ........ REMOVAL OF THERMOSTAT AND HOUSING....... REMOVAL OF THERMOSTAT AND HOUSING....... REMOVAL OF CYLINDER HEAD ........... DRAINING OIL FROM OIL COOLER...... REMOVAL OF COOLANT INLET CONNECTOR..... REMOVAL OF FAN HUB ASSEMBLY .... REMOVAL OF WATER PUMP................ REMOVAL OF VIBRATION DAMPER..... REMOVAL OF GEAR COVER ................ 13- 17 13- 18 13- 18 13- 19 13- 19 13- 20 13- 20 13- 20 13- 20 13- 21 13- 21 13- 21 13- 21 13- 22 13- 22 13- 22 13- 22 13- 23 13- 23 13- 23 13- 23 13- 24 13- 24 13- 24 13- 25 13- 25 13- 26 13- 26
114 SERIES
13-1
REMOVAL OF FRONT CRANKSHAFT SEAL ......... 13- 26 REMOVAL OF STARTING MOTOR........ 13- 26 REMOVAL OF COOLANT HEATER ....... 13- 27 REMOVAL OF FLYWHEEL..................... 13- 27 REMOVAL OF FLYWHEEL HOUSING ... 13- 27 REMOVAL OF OIL PAN ......................... 13- 27 REMOVAL OF SUCTION TUBE............. 13- 28 REMOVAL OF REAR CRANKSHAFT SEAL............ 13- 28 REMOVAL OF CAMSHAFT .................... 13- 28 REMOVAL OF VALVE TAPPET .............. 13- 30 MEASUREMENT OF OIL PUMP GEAR BACKLASH ........ 13- 30 REMOVAL OF OIL PUMP....................... 13- 31 REMOVAL OF ENGINE FRONT SUPPORT ........... 13- 31 REMOVAL OF GEAR HOUSING............ 13- 31 REMOVAL OF CARBON ACCUMULATED ON CYLINDER LINER..................... 13- 32 REMOVAL OF PISTON ASSEMBLY ...... 13- 33 REMOVAL OF PISTON PIN.................... 13- 34 REMOVAL OF PISTON RING................. 13- 34 REMOVAL OF MAIN BEARING CAP ..... 13- 35 REMOVAL OF MAIN BEARING (LOWER) ......................................... 13- 35 REMOVAL OF CRANKSHAFT................ 13- 36 REMOVAL OF MAIN BEARING (UPPER) ............... 13- 36 REMOVAL OF PISTON COOLING NOZZLE ........... 13- 36 TESTING PROTRUSION OF CYLINDER LINER ........................... 13- 36 REMOVAL OF CYLINDER LINER .......... 13- 37 REPLACEMENT OF EXPANSION PLUG ......................... 13- 38 REMOVAL OF EXPANSION PLUG ........ 13- 38 REMOVAL OF CYLINDER BLOCK FROM ENGINE STAND .................. 13- 39 ASSEMBLY OF ENGINE............................... 13- 40 INSTALL THE CYLINDER BLOCK TO THE ROLL-OVER STAND......... 13- 40 INSTALLATION OF CYLINDER LINER .. 13- 40 INSTALLATION OF TAPPET .................. 13- 45 INSTALLATION OF PISTON COOLING NOZZLE ........... 13- 45 INSTALLATION OF MAIN BEARING (UPPER) ............... 13- 46 INSTALLATION OF CRANKSHAFT ........ 13- 48 INSTALLATION OF MAIN BEARING (LOWER) .............. 13- 49 INSTALLATION OF MAIN BEARING CAP ...................... 13- 49 INSTALLATION OF CONNECTING ROD BOLT.............. 13- 52 INSTALLATION OF PISTON PIN............ 13- 53
MEASURING PISTON RING END GAP ......................................... 13- 53 INSTALLATION OF PISTON RING ......... 13- 54 INSTALLATION OF PISTON ASSEMBLY ........................ 13- 56 INSTALLATION OF GEAR HOUSING .... 13- 61 INSTALLATION OF OIL PUMP................ 13- 62 INSTALLATION OF CAMSHAFT ............. 13- 64 INSTALLATION OF WATER PUMP......... 13- 66 INSTALLATION OF OIL SUCTION TUBE ........................ 13- 66 INSTALLATION OF REAR CRANKSHAFT SEAL ............ 13- 66 INSTALLATION OF WEAR SLEEVE, REAR CRANKSHAFT SEAL ............ 13- 67 INSTALLATION OF OIL PAN .................. 13- 70 INSTALLATION OF TIMING PIN ASSEMBLY.................. 13- 71 INSTALLATION OF FLYWHEEL HOUSING..................... 13- 74 TESTING COAXIALITY OF FLYWHEEL HOUSING BORE ......... 13- 75 INSTALLATION OF FLYWHEEL.............. 13- 79 MEASURING RUNOUT OF FLYWHEEL BORE ........................... 13- 81 MEASURING FACE RUNOUT OF FLYWHEEL ................ 13- 83 INSTALLATION OF STARTING MOTOR ......................... 13- 84 INSTALLATION OF OIL COOLER........... 13- 84 INSTALLATION OF OIL FILTER.............. 13- 85 INSTALLATION OF CYLINDER HEAD.... 13- 85 INSTALLATION OF PUSH ROD.............. 13- 89 ASSEMBLY OF ROCKER LEVER AND SHAFT ..................................... 13- 89 INSTALLATION OF ROCKER LEVER ASSEMBLY ......... 13- 91 ADJUSTING VALVE CLEARANCE ......... 13- 92 INSTALLATION OF HEAD COVER ......... 13- 94 INSTALLATION OF CYLINDER BLOCK BREATHER TUBE............................ 13- 95 INSTALLATION OF INJECTOR............... 13- 95 INSTALLATION OF FUEL DRAIN MANIFOLD................. 13- 96 INSTALLATION OF ENGINE LIFTING BRACKET ........... 13- 96 INSTALLATION OF INTAKE MANIFOLD COVER ........... 13- 96 INSTALLATON OF AFTERCOOLER ....... 13- 97 INSTALLATON OF EXHAUST MANIFOLD ..................... 13- 97 INSTALLATION OF TURBOCHARGER .. 13- 98 INSTALLATION OF TURBOCHARGER OIL DRAIN TUBE ............................. 13- 99 INSTALLATION OF TURBOCHARGER OIL SUPPLY HOSE......................... 13-101
13-2
114 SERIES
INSTALLATION OF TURBOCHARGER EXHAUST OUTLET PORT CONNECTOR................................... 13-101 INSTALLATION OF CROSSOVER ......... 13-101 INSTALLATION OF THERMOSTAT AND HOUSING ............................... 13-101 INSTALLATION OF COOLANT OUTLET CONNECTOR .................. 13-102 INSTALLATION OF COOLANT AIR BLEED JOINT ........ 13-102 INSTALLATION OF COOLANT AIR BLEED VALVE ....... 13-102 INSTALLATION OF COOLANT AIR BLEED TUBE ......... 13-103 INSTALLATION OF COOLANT INLET CONNECTOR .... 13-103 INSTALLATION OF ALTERNATOR BRACKET ............... 13-103 INSTALLATION OF ALTERNATOR ....... 13-103 INSTALLATION OF ALTERNATOR BRACE.................... 13-104 INSTALLATION OF BELT TENSIONER BRACKET ........ 13-105 INSTALLATION OF BELT TENSIONER .......................... 13-105 REMOVAL FROM ENGINE ASSEMBLY STAND.......... 13-105 INSTALLATION OF FAN HUB ASSEMBLY ..................... 13-106 INSTALLATION OF FUEL INJECTION PUMP ................ 13-106 INSTALLATION OF FUEL INJECTION PUMP, FUEL SUPPLY LINE......................... 13-111 INSTALLATION OF FUEL FILTER HEAD 13-111 INSTALLATION OF FUEL FILTER.......... 13-112 INSTALLATION OF FUEL INJECTION PIPE (HIGH-PRESSURE SIDE) ............... 13-112 INSTALLATION OF BOOST COMPENSATOR TUBE..... 13-113 INSTALLATION OF FRONT CRANKSHAFT SEAL ......... 13-113 INSTALLATION OF FRONT CRANKSHAFT WEAR SLEEVE ............................... 13-113 INSTALLATION OF GEAR COVER ........ 13-116 INSTALLATION OF TACHOMETER DRIVE.................... 13-117 INSTALLATION OF CRANKSHAFT PULLEY, VIBRATION DAMPER ..................... 13-117 INSTALLATION OF BELT ....................... 13-118 INSTALLATION OF ENGINE FRONT SUPPORT ........... 13-118 INSTALLATION OF FUEL FEED PUMP.......................... 13-118
INSTALLATION OF FUEL PIPING TUBE (LOW-PRESSURE SIDE) ................ INSTALLATION OF FUEL PUMP SOLENOID ................. INSTALLATION OF AIR COMPRESSOR INSTALLATION OF ENGINE ACCESSORY ....................
13-119 13-119 13-119 13-121
114 SERIES
13-3
SPECIAL TOOL LIST
DISASSEMBLY AND ASSEMBLY
SPECIAL TOOL LIST

SPECIAL TOOLS FOR DISASSEMBLY AND ASSEMBLY
We recommend that you use the tools listed below. The tool to use is specified in the respective procedure. Tool No. Explanation of tool Sketch of tool
ST-647
Standard Puller Used to remove drive pulleys, impellers, air compressor counterweights, etc.
ST-1229
Cylinder Liner Driver Install cylinder liner in cylinder block.
ST-1325
Dial Gauge Attachment Attaches to crankshaft flange to provide measuring of flywheel and flywheel housing runout with dial bore gauge.
3375068
Cup Plug Sealant Used when installing pipe plugs, cup plugs, etc. on the engine to prevent leaks.
3375072
Dial Bore Gauge Kit Used to measure internal diameter bores from 78.5 mm [3.09 in] to 203.2 mm [8.0 in].
3375629
Universal Cylinder Liner Puller Remove cylinder liners from cylinder block. Requires Part No. 3822786 Cylinder Liner Puller Plate.
13-4
114 SERIES
SPECIAL TOOL LIST
Tool No.
Explanation of tool
Sketch of tool
3375049
Oil Filter Wrench Used to remove and install the lubricating oil filters.
3375194
Engine Stand Used to support engine block when assembling engine. Used together with adapter plate (Part No. 3822607).
3375957
Nylon lifting sling Used as an aid when removing or installing crankshaft, flywheel, or other heavy components.
3376015
Cylinder Liner Puller (Universal) Remove cylinder liners from the cylinder block. Requires two Part No. 3376649 Puller Arm Extension Feet.
3376050
Dial Indicator and Sleeve Assembly Use with Part No. ST-1325 Dial Gauge Attachment to measure fly wheel and flywheel housing runout. Use with magnet base (Part No. 3377399) to provide measuring of gear end clearance and backlash.
3377371
Engine Barring Gear Used to engage the flywheel ring gear to rotate the crankshaft.
3377399
Magnet base dial indicator holder Used together with dial indicator and sleeve assembly (Part No. 3376050).
114 SERIES
13-5
SPECIAL TOOL LIST
Tool No.
Explanation of tool Cylinder Liner Clamp Set Used to clamp the liner into the bore of the cylinder block. Note: Requires two cylinder head capscrews (not included in the clamp set).
Sketch of tool
3822503
3822512
Engine lifting tool Used when lifting engine.
3822607
Adapter plate Used when installing engine to engine stand (Part No. 3375194).
3823137
Piston Ring Expander Used to install piston rings onto pistons without damaging or distorting the rings.
3824469
Fuel Pump Gear Puller Used to pull the fuel pump gear.
3823276
Injector Puller Used to pull injectors.
3823290
Piston Ring Compressor Used to compress the piston rings while installing the pistons into the cylinder bores.
13-6
114 SERIES
SPECIAL TOOL LIST
Tool No.
Explanation of tool
Sketch of tool
3823425
Crowfoot Wrench Used to torque high pressure fuel line nuts on Aor MW Bosch fuel pump. Size: 10 mm, 17 mm, 3/8 in. drive.
3823494
Sealant, Three Bond (150 Gram Tube) Used for sealing T joints and front gear cover.
3823495
Gauge Block Measure cylinder liner protrusion on the cylinder block.
3823818
Main Bearing Rollout Tool Used to remove and install main bearings with the crankshaft installed.
3823878
Torque angle gauge Used when applying torque to mounting bolts using torque + angle method.
3823908
Wear sleeve screwdriver Used when installing front crankshaft oil seal wear sleeve.
3823956
Fuel injection pump installation tool kit Used when removing or installing mounting bolts inside fuel injection pump body.
114 SERIES
13-7
OUTLINE OF DISASSEMBLY AND ASSEMBLY OF ENGINE
OUTLINE OF DISASSEMBLY AND ASSEMBLY OF ENGINE

OUTLINE
The procedure explained below is for the 114 series engine. The explanation also mentions differences in the engine model because of the purpose, optional equipment for the engine, and the year of assembly of the engine. Omit any procedure that is not related to your engine. Warning: A Warning is clearly given for any component or assembly if its weight exceeds 23 kg. When installing or removing, use a hoist or ask for assistance, and take care to prevent injury. Caution: The fasteners are given in the metric system. Basically, all fasteners have righthand threads. If any fastener has a left-hand thread, it is cleared indicated. Disassembly The explanation of the procedure for disassembly of the engine is given in the logical order. This is not simply the order for disassembling the engine. Depending on the part, it may be necessary to remove it in the order explained. Always follow this order until you fully understand the engine. Dispose of all gaskets, seals, hoses, filters, and Orings. If they are necessary for analysis of any failure, keep these parts in a safe place. When removing the parts , fix labels, tags, or make marks to show the position of the part. This helps in identifying parts related to any failure, and also makes the assembly procedure easier. Before removing any special components from the engine, fix labels or tags, or make marks, or take photographs. The installation of special optional component is not included in the assembly procedure. When applying force to remove any part, use a mallet. When using a mallet, always remove the fasteners first. Be careful not to let dirt get on the parts during assembly. If dirt accumulates, it is difficult to clean the components. Assembly The assembly procedure assumes that all components and assemblies have been cleaned, replaced, and reassembled, and that preparations have been made to install them to the engine. The torque values for each procedure are given. Many gaskets and O-rings are made from material designed to absorb oil. If the gaskets or O-rings come into contact with oil, they expand and the sealing effect is increased. When installing these parts, use only the recommended adhesive or vegetable oil.
13-8
114 SERIES
OVERALL DISASSEMBLY OF ENGINE

ENGINE LIFTING TOOL AND BRACKET
Warning:The engine lifting tool must be designed so that it can lift the engine assembly safely. The dry weight of the engine with the standard accessories installed is 612 kg. Use a hoist and engine lifting tool (Part No. 3822152) of the correct rating. It is installed to the engine lifting bracket and used to raise the engine. Install engine to two appropriate engine support stands.
PREPARATION FOR STEAM CLEANING OF ENGINE

Install plastic caps or tape to all the openings in the engine to prevent any moisture or dust from entering the engine. Put covers on all the electrical components to prevent damage caused by water.
STEAM CLEANING OF ENGINE

Warning:When cleaning with steam, wear protective clothing, safety glasses, and face shield. Hot steam may cause serious burns. Caution: Fit covers to the openings of the engine and to the electrical components, and be careful not to get water on these parts. Use steam to clean off any excessive dirt on the outside of the engine.
114 SERIES
13-9
DRAINING OIL
17mm Caution: The total amount of lubricating oil including the oil inside the oil filter is 23.8 liters. Remove the drain plug and dispose of the seal washer of the drain plug. Then drain the oil.
DRAINING COOLANT
Open the drain valve at the bottom of the oil cooler housing.
REMOVAL OF OIL FILTER

Part No. 3375049 Filter wrench Remove the oil filter and discard if there is no need to analyze the failure.
13-10
114 SERIES
REMOVAL OF FUEL FILTER

75-80 mm, 90-95 mm strap wrenches Remove the fuel filter and seal ring, and discard.
REMOVAL OF FUEL SUPPLY PIPE (LOWPRESSURE SIDE)

20mm, 19mm, 17mm, 14mm, 10mm Disconnect low-pressure side fuel line. Caution: To prevent damage to the fuel feed pump, use 2 wrenches when loosening of the low-pressusre line. Dispose of all copper washers.
REMOVAL OF FUEL FEED PUMP

10mm Remove the fuel feed pump.
114 SERIES
13-11
REMOVAL OF FUEL SUPPLY PIPE (HIGHPRESSURE SIDE)

10mm, 17mm, 19mm Remove high-pressure side fuel injection pipe.
Caution: To prevent damage from dirt, cover the outlet port connectors on the high-pressure side of the fuel injection pump and the injectors.
REMOVAL OF FUEL INJECTION PUMP FUEL SUPPLY PIPES

17 mm, 19 mm Remove the fuel injection pump fuel supply pipe and fuel return pipe.
REMOVAL OF BOOST COMPENSATOR TUBE

13mm, 16mm Remove the boost compensator tube.
13-12
114 SERIES
REMOVAL OF TACHOMETER DRIVE

Remove the tachometer drive or access cap of gear cover if they are installed.
REMOVAL OF FUEL INJECTION PUMP

22mm (PES6A Fuel injection pump) 27mm (PES6MW Fuel injection pump) 30mm (PES6P Fuel injection pump) Remove the nut and lock washer from fuel injection pump shaft.
Fuel injection pump gear puller (Part No. 3823259) Pull fuel injection pump drive gear and disconnect from shaft.
114 SERIES
13-13
10mm, 13mm Engines equipped with the PES6P fuel injection pump the support brackets must be removed.
15mm, fuel injection pump installation tool kit (Part No. 3823956) Remove 4 mounting nuts. Remove the fuel injection pump.
REMOVAL OF AIR CONDITIONER COMPRESSOR

Remove the inlet and outlet air connectors from air compressor when having been installed.
15/16 inch Remove the inlet and outlet of coolant pipe from air compressor.
13-14
114 SERIES
9/16 inch Remove the oil supply pipe.
19mm, 15mm, 13mm Remove the air conditioner compressor support bracket and mounting bolts. Remove the air conditioner compressor.
INSTALLATION OF ENGINE TO ENGINE STAND

Engine lifting tool (Part No. 3822512) Caution: Dry weight of engine: 860 kg (differs according to machine model) Use a engine lifting bracket (Part No. 3822512) to raise the engine.
Install the adapter plate (Part No. 3822607) to the engine stand (Part No. 3375194) using 5 mounting bolts of 4 grade (1/2 x 13 x 1-1/2 inch).
3 Mounting bolt : 95 Nm {9.7 kgm}
114 SERIES
13-15
Install adapter plate to cylinder block end using 4 mounting bolts (M10 x 1.5 x 20 mm) and 2 mounting bolts (M8 x 1.25 x 20 mm). Bolt position A B, C Bolt size M8 M10 Tightening torque value 24 Nm {2.4 kgm} 40 Nm {4.1 kgm}
REMOVAL OF TURBOCHARGER EXHAUST OUTLET CONNECTOR

7/16 inch, 15 mm Remove the turbocharger exhaust outlet connector.
REMOVAL OF WESTGATE ACTUATOR HOSE

Screwdriver Remove the westgate.
REMOVAL OF CYLINDER BLOCK BREATHER TUBE

13mm, 18mm Remove mounting bolts (A) and (B) of cylinder block breather tube support bracket.
13-16
114 SERIES
REMOVAL OF CROSSOVER TUBE

Screwdriver Remove the crossover tube.
REMOVAL OF INTAKE MANIFOLD COVER

10mm Remove the intake manifold cover plate (SA6D114E2).
REMOVAL OF AFTERCOOLER
8mm Remove the coolant supply tube return tube (SA6D114E-2). and the coolant
10mm Remove the aftercooler housing and gasket.
114 SERIES
13-17
REMOVAL OF FUEL DRAIN MANIFOLD

10mm Remove the fuel drain manifold, then remove the seal washer.
REMOVAL OF INJECTOR
10mm, injector puller (Part No. 3823276) Remove the injector.
Remove the seal washer, then discard.
13-18
114 SERIES
REMOVAL OF CYLINDER HEAD COVER

15mm Remove the cylinder head cover.
Remove the cylinder head cover seal, mounting bolts, and O-ring.
REMOVAL OF ROCKER LEVER

14 mm, screwdriver Loosen the rocker lever adjustment screw until it stops.
10 mm Remove the rocker lever assembly and oil manifold.
114 SERIES
13-19
REMOVAL OF PUSH ROD

Remove the push rod.
REMOVAL OF TURBOCHARGER OIL SUPPLY HOSE

16 mm, 19 mm Remove the turbocharger oil supply line.
REMOVAL OF TURBOCHARGER OIL DRAIN TUBE

10 mm, screwdriver Remove the turbocharger oil drain tube.
REMOVAL OF TURBOCHARGER
15 mm Remove the turbocharger.
13-20
114 SERIES
REMOVAL OF EXHAUST MANIFOLD

16 mm Remove the exhaust manifold.
REMOVAL OF DRIVE BELT

3/8 inch square screwdriver Remove the drive belt.
REMOVAL OF BELT TENSIONER

13 mm Remove the belt tensioner.
REMOVAL OF BELT TENSIONER BRACKET

5 mm, hexagonal wrench Remove the belt tensioner bracket.
114 SERIES
13-21
REMOVAL OF ALTERNATOR BRACKET

10 mm, 19 mm Remove mounting bolt (A) of the alternator bracket. Remove mounting bolt (B) of the rear support bracket.
REMOVAL OF ALTERNATOR
15 mm, 18 mm, 19 mm Remove the bolt and nut for installing the alternator. Remove the alternator.
REMOVAL OF ALTERNATOR BRACKET

13 mm Remove the alternator bracket.
REMOVAL OF COOLANT OUTLET CONNECTOR

10 mm Remove the coolant outlet connector.
13-22
114 SERIES
REMOVAL OF COOLANT AIR BLEED TUBE

9/16 inch Remove the coolant air bleed tube.
REMOVAL OF COOLANT AIR BLEED VALVE

7/16 inch Remove the coolant air bleed valve.
REMOVAL OF THERMOSTAT AND HOUSING

10 mm Remove the thermostat housing and thermostat.
REMOVAL OF THERMOSTAT AND HOUSING

1/2 inch Remove the 1/8 inch brass joint from cylinder head.
114 SERIES
13-23
REMOVAL OF CYLINDER HEAD

16 mm Remove the cylinder head capscrews in the sequence shown in the illustration.
The weight of the components is 74 kg. When removing the cylinder head, use a hoist. To prevent damage to the combustion surface, lift the cylinder head directly up when removing.
DRAINING OIL FROM OIL COOLER

10 mm Caution: Because of the design of the present oil cooler cover, approx. 0.7 liters of oil remains after the oil is drained. When removing the cover, set a container under the oil cooler to catch the oil. Remove the oil cooler, element, and gasket.
REMOVAL OF COOLANT INLET CONNECTOR

Screwdriver Remove the coolant inlet connector.
13-24
114 SERIES
REMOVAL OF FAN HUB ASSEMBLY

13 mm, 10 mm Remove the fan hub assembly.
REMOVAL OF WATER PUMP

13 mm Remove the water pump.
Remove the O-ring and discard.
Engine crankshaft rotating tool (Part No. 3377371) When loosening the damper mounting bolts, use the engine crankshaft rotating tool and prevent the engine from rotating.
114 SERIES
13-25
REMOVAL OF VIBRATION DAMPER

18 mm Remove the vibration damper.
REMOVAL OF GEAR COVER

10 mm Remove the gear cover.
REMOVAL OF FRONT CRANKSHAFT SEAL

Hammer, punch Hit the seal from the gear cover and push out.
REMOVAL OF STARTING MOTOR

12 mm Remove the starting motor.
13-26
114 SERIES
REMOVAL OF COOLANT HEATER

Remove the engine coolant heater.
REMOVAL OF FLYWHEEL
18 mm Remove 2 mounting bolts at a 180 interval. Install 2 guide pins (M12 x 1.25 x 90 mm). 5 For machines fitted with a clutch, the threads of the mounting bolt hole for the clutch pressure plate are metric or standard parts. Always use the correct mounting bolts. Measure the size and design of the thread of the mounting bolts, then install 2 T-handles at point and point of the flywheel. Remove 6 remaining flywheel mounting bolts. Remove the flywheel from the guide pin.
REMOVAL OF FLYWHEEL HOUSING

15 mm Remove the flywheel housing.
REMOVAL OF OIL PAN

10 mm Rotate the engine on the stand and remove the oil pan, and gasket.
114 SERIES
13-27
REMOVAL OF SUCTION TUBE

8 mm Remove the suction tube and gasket.
REMOVAL OF REAR CRANKSHAFT SEAL

8 mm Remove the rear seal housing and gasket.
Support the rear seal housing, then push the seal, and knock it out.
REMOVAL OF CAMSHAFT
Measurement of gear backlash Put the tip of a dial gauge in contact with the teeth of the camshaft gear and determine the position.
13-28
114 SERIES
Be careful of camshaft gear backlash (A). If the backlash exceeds the limit, make marks on the camshaft gear and crankshaft gear to carry out investigation. Limit of camshaft gear backlash mm Min. 0.080 Max. 0.33 5 When investigating the backlash, if the contacting gears are not held in position, the measurement will be the total for both gears. Before removing the camshaft, rotate the crankshaft and align the timing mark.
15 mm Remove the camshaft thrust plate mounting bolts.
Remove the camshaft and thrust plate from the cylinder block. Be careful not to drop the thrust plate. For details of cleaning and inspecting the camshaft, see TESTING AND ADJUSTING.
114 SERIES
13-29
REMOVAL OF VALVE TAPPET

Electric pencil Remove the tappet and make a mark at the point indicated in the diagram. Caution: If the camshaft and tappet are to be used again, to prevent the wear of the camshaft from advancing, the tappet must conform to the companion rope at the top of the camshaft. When removing, dispose of any tappet where the mark cannot be seen.
MEASUREMENT OF OIL PUMP GEAR BACKLASH

Put the tip of the dial gauge in contact with the gear tooth to determine the position.
Be careful of the drive gear backlash. If the backlash exceeds the limit, make marks on the drive gear and idler gear to carry out further analysis. Caution: When investigating the backlash, if the contacting gears are not held in position, the measurement will be the total for both gears. Limit of oil pump drive gear backlash (A) mm Min. 0.080 Max. 0.33 Put the tip of the dial gauge in contact with the pump idler gear tooth to determine the position.
13-30
114 SERIES
Be careful of the idler camshaft gear backlash. If the backlash exceeds the limit, make marks on the idler gear and crankshaft gear to carry out further analysis. Caution: When investigating the backlash, if the contacting gears are not held in position, the measurement will be the total for both gears. Limit of oil pump drive gear backlash (A) mm Min. 0.080 Max. 0.33
REMOVAL OF OIL PUMP

13 mm Remove the oil pump. 5 For details of cleaning and inspecting, see TESTING AND ADJUSTING.
REMOVAL OF ENGINE FRONT SUPPORT

15 mm Remove the front engine support at the engine end.
REMOVAL OF GEAR HOUSING

10 mm Remove the mounting bolts, gear housing, and gasket.
114 SERIES
13-31
If gear housing (4) is not replaced, do not remove timing pin assembly (2). For details of the procedure for replacing the timing pin assembly, see OVERALL ASSEMBLY OF ENGINE in this section.
REMOVAL OF CARBON ACCUMULATED ON CYLINDER LINER

Caution: When removing the carbon from the cylinder liner and cylinder head mounting surface of the cylinder block, do not use sandpaper or emery cloth. The aluminum oxide or silicon particles coming from the sandpaper or emery cloth may cause serious damage to the engine. Rotate the crankshaft and set so that the area where the carbon is accumulated appears above the area of movement of the ring of the cylinder liner. Warning: When carrying out the following procedure, wear protective glasses. If the brush is a motor driven type, check that it matches the rotating speed of the wire brush.
Use a rotating wire brush and remove the carbon from the top of the cylinder liner. Do not use a steel wire wheel in the area of the piston stroke. Move the handle in a circular movement to remove the accumulated carbon. Use paper which does not leave threads and remove all the particles of broken wire and removed carbon from the cylinder.
13-32
114 SERIES
If a rotating wire brush cannot be used, use a scraper with an aluminum blade. Use Scotch Brite 7447 (Part No. 3823258) or equivalent fine fiber polishing pad and remove the remaining carbon.
REMOVAL OF PISTON ASSEMBLY

Make a mark on each connecting rod cap according to the cylinder.
Make a mark on each piston according to the cylinder. Caution: Do not stamp marks on pistons that have been given anodizing treatment. Stamping a mark will damage the anodizing film. Write the mark on such pistons.
19 mm, plastic hammer Remove the nut from connecting rod cap mounting bolts. Tap the connecting rod cap mounting bolts, and loosen the connecting rod cap. Remove the lower connecting rod bearing. Mark the cylinder No. and the letter "L" (Lower) on the flat surface of the bearing tongue.
114 SERIES
13-33
Hold the piston with your other hand, then push the connecting rod and piston assembly from the cylinder bore. Be careful not to damage the crankshaft journal.
To prevent damage, set the connecting rod and piston assembly on a rack. Caution: When using again, to make the worn mating surface match properly, install the piston and connecting rod assembly in the cylinder with the same number (the cylinder that it was removed from). Using a tag, mark the cylinder No. on each piston and connecting rod assembly after removing.
REMOVAL OF PISTON PIN

Using snap ring pliers, remove the stopper rings on both sides of the piston. Remove the piston pin. 5 There is no need to heat the piston.
REMOVAL OF PISTON RING

Piston ring expander (Part No. 3823137) Using piston ring expander (Part No. 3823137), remove the piston ring. Put a tag on the piston ring, and then record the cylinder No. of the piston on the tag.
13-34
114 SERIES
REMOVAL OF MAIN BEARING CAP

19 mm Rotate the engine to the horizontal position, then remove the mounting bolts of the main bearing cap.
Mark the number on the main bearing cap. Use a steel stamp to mark the number on the main bearing cap before removing the main bearing cap.
Remove the main bearing cap. 5 Do not use a lever to open the main bearing cap mounting bolts and remove from the cylinder block. Using 2 main bearing caps, move the bearing cap slightly and loosen it, taking care not to damage the thread of the mounting bolts.
REMOVAL OF MAIN BEARING (LOWER)

Remove the lower main bearing from the main bearing cap. Mark the number of the journal that was removed from the main bearing on the flat surface of the protruding portion of the main bearing. Do not make marks on the surface connecting the main bearing and crankshaft. If the main bearing is used again, it may damage the engine.
114 SERIES
13-35
REMOVAL OF CRANKSHAFT
5 The weight of the component is more than 23 kg. When removing the crankshaft, use a hoist or ask another worker for assistance. To prevent damage to the crankshaft or cylinder block, lift the crankshaft straight up. Install a nylon lifting sling (Part No. 3375957) around the rod bearing journal of No. 3 and No. 4. Install the lifting sling to the hoist, then remove the crankshaft.
REMOVAL OF MAIN BEARING (UPPER)

Remove the upper main bearing using both thumbs. When removing the main bearing from the main journal, mark the number of the journal on the flat surface of the protruding portion of the main bearing. Do not make marks on the surface connecting the main bearing and crankshaft. If the main bearing is used again, it may damage the engine.
REMOVAL OF PISTON COOLING NOZZLE

3/16 inch piston punch Remove the piston cooling nozzle and discard it.
TESTING PROTRUSION OF CYLINDER LINER

Gauge block (Part No. 3823495) The protrusion of the cylinder liner is the distance that the cylinder liner protrudes above the surface of the block. Before removing the liner, check the protrusion when the liner is not held in position. Protrusion of cylinder liner mm Min. 0.025 Max. 0.122 If the protrusion of the cylinder liner exceeds the limit, the counterbore must be machined and shims must be added to set to the original standard value.
13-36
114 SERIES
REMOVAL OF CYLINDER LINER

When removing the cylinder liner, two types of equipment can be used. Universal liner puller (Part No. 3376051) with extension foot (Part No. 3376649) Universal liner puller (Part No. 337562) with plate (Part No. 3376049)
Cylinder liner puller (Part No. 3376015) Caution: To avoid damage to the cylinder block, install the cylinder liner using the specified procedure. The puller must not contact the block at points , , , or . Insert the cylinder liner puller from the top of the cylinder block.
The cylinder liner puller must be aligned with the center at the top of the cylinder liner block. Turn the jack bolt of the cylinder liner puller clockwise to loosen the cylinder liner from the cylinder block. Using both hands, remove the cylinder liner.
Universal liner puller (Part No. 3375629) Caution: To avoid damage to the cylinder block, install the cylinder liner using the specified procedure. Set the cylinder liner puller plate parallel to the main bearing saddle. It must not extend outside the outside diameter of the cylinder liner. Insert the cylinder liner puller from the top of the cylinder block.
114 SERIES
13-37
The cylinder liner puller must be aligned with the center at the top of the cylinder liner lock. Turn the jack bolt of the cylinder liner puller clockwise to loosen the cylinder liner from the cylinder block. Using both hands, remove the cylinder liner.
Use a Daiken or equivalent part, and mark the cylinder No. on top of each cylinder liner. Remove the O-ring and discard it.
REPLACEMENT OF EXPANSION PLUG

When using a high-temperature bath spray washer or equivalent device to wash the components, all the expansion plugs must be replaced. This washing procedure reduces the amount of sealant at the seal portions and reduces the sealing effect.
REMOVAL OF EXPANSION PLUG

Remove the expansion plug as follows. Using a hammer and center punch, make a mark on the expansion plug to make a hole with the drill. Make a 3 mm hole in the expansion plug with the drill. Using a dent puller, remove the expansion plug.
For details of the position of the expansion plugs and the method of distinguishing, see REBUILDING AND REPLACING.
13-38
114 SERIES
REMOVAL OF CYLINDER BLOCK FROM ENGINE STAND

13 mm Remove the cylinder block from the roll-over stand. The weight of the component is more than 23 kg. Use a hoist when removing the cylinder block. For details of cleaning and inspecting the cylinder block, see REBUILDING AND REPLACING, Checks when reusing cylinder block.
114 SERIES
13-39
ASSEMBLY OF ENGINE
ASSEMBLY OF ENGINE
INSTALL THE CYLINDER BLOCK TO THE ROLL-OVER STAND
Caution: Check that the cylinder block has been cleaned and inspected. Caution: The weight of the component is more than 23 kg. Use a hoist when installing the cylinder block. Use a hoist and engine lifting sling (Part No. 3375957) and raise the cylinder block.
Use the adapter plate (Part No. 3822607) together with the engine stand (Part No. 3375194).
Using 4 mounting bolts (M10 x 1.5 x 20 mm) and 2 mounting bolts (M8 x 1.25 x 20 mm), install the adapter plate to the fuel injection pump end of the cylinder block. Bolt position A B, C Bolt size M8 M10 Tightening torque value 24 Nm {2.4kgm} 40 Nm {4.1kgm}
INSTALLATION OF CYLINDER LINER

Caution: Clean and remove all accumulated carbon and pieces from seal surfaces A, B, and C. Use Scotch Brite 7448 or the equivalent and detergent, and polish the surface. The tolerance limit is important for machining, so be careful not to grind too much. For details of inspection of the cylinder liner counterbore, see the procedure in REBUILDING AND REPLACING, Checks when reusing cylinder block. Coat surfaces A and B with clean 15W-40 engine oil.
13-40
114 SERIES
ASSEMBLY OF ENGINE
When reusing the cylinder liner, install the cylinder to the same position, then rotate the liner 45 (1/8 turns) from its original position. If it is installed correctly, the cylinder liner pitting is positioned as shown in the diagram. As a result, the pitted surface is moved away from the place where the pitting is caused.
Coat the O-ring seal portion of cylinder liner with clean 15W-40 engine oil. Install the O-ring to the cylinder liner. 5 Coat the O-ring seal portion of the cylinder liner with oil, then install the cylinder liner within 15 minutes. When installing, check that the O-ring of the cylinder liner is not twisted or damaged.
Cylinder liner driver (Part No. ST-1229) Install cylinder liner inside cylinder block. Using a cylinder liner driver (Part No. ST-1229) and leather hammer, knock the cylinder liner into the bore. 5 If the cylinder liner does not fit in the counterbore seat of the cylinder block, remove the cylinder liner. Check that the counterbore seat and cylinder liner have no chipping, flashes, or dirt. Then install the cylinder liner again. Liner clamp set (Part No. 3822503) Using 2 cylinder head mounting bolts, determine the position of the 2 cylinder liner clamps as shown in the diagram. Tighten the mounting bolts.
3 Mounting bolt : 68 Nm {6.9 kgm}
Remove the clamp, then repeat this procedure until all the cylinder liners are clamped.
114 SERIES
13-41
ASSEMBLY OF ENGINE
Cage block (Part No. 3323495) The protrusion of the cylinder liner is the distance that the cylinder liner protrudes from the top surface of the block. Measure the protrusion of the cylinder liner at four points 90 apart. Protrusion of cylinder liner mm Min. 0.025 Max. 0.122
If the difference in the cylinder liner protrusion between two points 180 apart exceeds 0.025 mm, Install the cylinder liner clamp again and tighten.
Check the cylinder liner protrusion again.
If the cylinder liner protrusion differs and exceeds 0.025 mm, Remove the cylinder liner.
13-42
114 SERIES
ASSEMBLY OF ENGINE
Check that the cylinder liner seal engine has no flashes, dirt, or breakage. If there is any damage to the cylinder liner, replace it. Install the cylinder liner again. Check the protrusion of the cylinder liner.
Hint for maintenance: If the cylinder liner exceeds the limit by even a small amount, and another new cylinder liner is installed to the bore which exceeds the limit, the total of the tolerance limit may bring the protrusion of the cylinder liner within the permitted range.
If the protrusion of the cylinder liner cannot fulfill the specified conditions, machine the counterbore of the cylinder block liner, add a counterbore shim, and adjust the protrusion of the cylinder liner to the correct standard.
Using a thickness gauge, check the clearance between the cylinder liner and block at four points around the casing. Limit for clearance between cylinder liner and block mm Min. 0.229
114 SERIES
13-43
ASSEMBLY OF ENGINE
If the clearance between the cylinder liner and block is less than 0.229 mm, Remove the cylinder liner.
Check that there is no dirt or damage to the cylinder liner and cylinder block.
Check that there is no dirt or damage to the cylinder liner and cylinder block. Check that there is no dirt or damage to the cylinder liner and cylinder block.
Measure the cylinder liner bore at points , , , , and to check the difference from the roundness. Measure the points in directions AA and BB. The difference from the roundness of the cylinder liner bore must not exceed 0.08 mm.
13-44
114 SERIES
ASSEMBLY OF ENGINE
If the difference from the roundness of the cylinder liner bore exceeds 0.08 mm, Remove the cylinder liner so that it is possible to measure the cylinder block liner bore.
INSTALLATION OF TAPPET
Caution: Install the tappet as follows. When reusing the camshaft and tappet, the tappet must conform with the companion rope of the camshaft. If no mark was made on the tappet when it was removed, that tappet cannot be used again. A used tappet must not be installed to a new camshaft. When reusing the camshaft, if the used tappet conforms with the companion rope of the camshaft, a used tappet can be used together with a new part.
Coat tappet head, stem, and socket with Lubriplate 105. Install tappet.
INSTALLATION OF PISTON COOLING NOZZLE

23 mm Install main bearing cap.
114 SERIES
13-45
ASSEMBLY OF ENGINE
1/2 inch center punch Install the piston cooling nozzle so that it is level with the bearing saddle surface or below it. 5 5 If the piston cooling nozzle has been removed, use a new piston cooling nozzle. Because of the relationship between the position of the nozzle and the angle of the spray, there is no need for a bore in the No. 3 main bearing saddle.
Make sure that the spray hole is clean and not clogged. 5 When washing, be careful not to damage the hole in the piston cooling nozzle.
INSTALLATION OF MAIN BEARING (UPPER)

There are two oil holes in the upper bearing. There are no oil holes in the lower bearing. Both the upper main bearing and lower main bearing have a mark on the rear side showing the standard (STD) or oversize (OS) thickness. 5 With the main bearing, it is possible to use a crankshaft machined to 1 mm undersize from the original diameter. For the connecting rod and main bearing journal, the crankshaft machined to undersize has a mark on the counterweight at the front. If there is a mark on the crankshaft, check the part number of the main bearing and connecting rod to ensure that the correct bearing size is used.
13-46
114 SERIES
ASSEMBLY OF ENGINE
must fit in Caution: Bearing protrusion portion groove of the bearing saddle to ensure that the bearing is correctly positioned and to prevent damage to the engine. Install the upper bearing. 5 When installing used bearings, install them to the original position on the engine. When disassembling, it is necessary to mark the main bearing journal No. on the protruding portion of the bearing. 5 Do not install the combination of thrust and main bearing to the center journal. After installing the crankshaft, the combination of thrust and main bearing will rotate.
Coat the main bearing with Lubriplate 105. Do not coat the rear face of the main bearing. Caution: Be careful not to let dirt get into the lubricant. If the lubricant is dirty, there will be premature wear of the main bearing.
114 SERIES
13-47
ASSEMBLY OF ENGINE
INSTALLATION OF CRANKSHAFT
Use a cloth which does not leave threads. Clean the crankshaft bearing journal.
The weight of the component is more than 23 kg. When removing the crankshaft, use a hoist. Use a hoist and nylon sling (Part No. 3375957) and raise the cylinder block. Install a nylon lifting sling (Part No. 3375957) around the connecting rod bearing journal of No. 3 and No. 4. When installing the crankshaft, be careful not to damage or move the main bearing. Install the crankshaft. Install six upper bearings to the specified position on the cylinder block, then install the crankshaft and check that the thrust bearing can be used normally. Coat the top thrust bearing with clean Lubriplate 105 or equivalent.
Main bearing roll-out tool (Part No. 3823318) Determine the position of the new thrust bearing on the crankshaft, and install as far as possible by hand. Using the main bearing roll-out tool (Part No. 3823818) and the engine rotation tool (Part No. 3377371), push in the bearing slowly as far as it will go so that it is aligned with the center of the block.
13-48
114 SERIES
ASSEMBLY OF ENGINE
INSTALLATION OF MAIN BEARING (LOWER)

Align protrusion with groove of the main bearing cap, and install the lower main bearing. Coat the inside of the main bearing with Lubriplate 105 or equivalent.
INSTALLATION OF MAIN BEARING CAP

Position numbers are given for the main bearing caps. No. 1 is at the front of the cylinder block. The numbers face the camshaft side of the engine. If they are installed properly, the protruding portions (grooves) of the main bearing will both be on the same side.
Set the main bearing and main bearing cap on top of the crankshaft.
There is no protrusion or groove on the thrust bearing journal. It is necessary to take care that the number stamped on the main bearing cap comes on the camshaft side of the engine.
114 SERIES
13-49
ASSEMBLY OF ENGINE
Coat the thread and the bottom of the bolt head of the main bearing cap mounting bolts with clean engine oil.
Small plastic hammer or rubber hammer Tap in the main bearing cap carefully to the specified position. 5 Check that the centers of the main bearing and cap are aligned. After pushing into the specified position, it is possible to tighten the mounting bolts of the main bearing cap by hand.
19 mm Tighten the main bearing cap mounting bolts uniformly in the order given in the diagram. When tightening the mounting bolts, tighten as follows. Step 1 2 3 Torque 50 Nm {5.1 kgm} 119 Nm {12.1 kgm} 176 Nm {17.9 kgm}
After the main bearing is tightened, the crankshaft must be able to rotate freely. If the crankshaft does not rotate freely, check the installation and size of the main bearing.
13-50
114 SERIES
ASSEMBLY OF ENGINE
Do as follows to measure the crankshaft and end clearance. Install a dial gauge (Part No. 3376050) to the oil pan flange. Put the tip of the gauge in contact with the crankshaft counterweight. Push the crankshaft towards the rear of the cylinder block.
Align the dial indicator to 0. Push the crankshaft towards the front of the cylinder block. If the end clearance is less than 0.127 mm, do as follows.
Turn the mounting bolt of the main bearing cap one turn. Push the crankshaft towards the front of the cylinder block, then push it towards the rear.
Tighten the main bearing cap mounting bolts in the order given in the diagram to the tightening torque given in the installation procedure chart.
114 SERIES
13-51
ASSEMBLY OF ENGINE
Measure the end clearance of the crankshaft. The standard for the end clearance is 0.127 mm 0.32 mm if the crankshaft is new or the crankshaft has been machined and a new thrust bearing has been fitted to it.
For crankshafts where the thrust bearing contact surface has been machined, the mark made on the oversize thrust bearing for the rear crankshaft counterweight is marked on the crankshaft. If there is a mark on the crankshaft counterweight, check the Part No. of the thrust bearing to check that the correct size is being used. Example: 0.010 = 0.25 mm
If the crankshaft end clearance on the engine being used exceeds 0.533 mm, remove the crankshaft from the engine and replace it.
INSTALLATION OF CONNECTING ROD BOLT

Plastic hammer Tap in the connecting rod bolt until the bolt head enters the specified position and is aligned with the center of the flat machined surface of the connecting rod.
13-52
114 SERIES
ASSEMBLY OF ENGINE
INSTALLATION OF PISTON PIN

Coat the connecting rod piston pin hole and the piston pin with clean 15W-40 engine oil.
Caution: Set so that the FRONT mark on the piston and the numbers on the connecting rod and connecting rod cap are facing in the direction shown in the diagram.
Snap ring pliers 5 There is no need to heat the piston when installing the piston pin. However, for this operation, it is necessary to keep the piston at room temperature or above. 5 Seat the retainer ring completely inside the piston pin hole to prevent any damage to the engine when the engine is running. Install a new retainer ring in the piston pin hole. Align the center of the piston pin hole in the connecting rod with the center of the piston pin hole in the piston and install the secondary retainer.
MEASURING PISTON RING END GAP

With the crankshaft perpendicular, rotate the engine on the engine stand so that the crankshaft gear faces up. 5 If the engine is rotated more than 90, the tappet will fall out.
114 SERIES
13-53
ASSEMBLY OF ENGINE
To check the piston ring in gap, use the top end of the piston and align the piston ring with the wear area of the cylinder liner being used. A= 89mm
Using a thickness gauge, measure the clearance of the piston ring. If the ring does not fulfill the following standards, replace the ring. Limit for gap in new piston ring mm Top Min. 0.35 Max. 0.60 Second Min. 0.35 Max. 0.65 Oil Min. 0.35 Max. 0.60 5 The piston ring in gap increases by 0.09 mm for every increase of 0.03 mm in the wear of the cylinder liner up to the maximum wear limit. Identify the ring sets for installation in the cylinder in which the end gap measured.
INSTALLATION OF PISTON RING

The top surface of the top and second ring is distinguished by the TOP mark, dot, or other distinguishing mark used by the manufacturer. Assemble so that the TOP mark or other distinguishing mark is facing up. With the oil ring, either surface can be set facing up.
13-54
114 SERIES
ASSEMBLY OF ENGINE
Install a 2-piece oil ring so that the gap in the expander ring and the end gap in the oil ring are 180 apart.
Piston ring expander (Part No. 3823137) Install the expander ring to the piston. Position the expander ring in the oil ring groove.
Install the oil ring so that the end gap in the oil ring and the gap in the expander ring are on opposite sides.
There are two types of second ring. A: Rectangular type B: Reverse twist When checking which type of ring is necessary, look at the control parts list (CPL) number on the data plate. Install the second ring.
114 SERIES
13-55
ASSEMBLY OF ENGINE
Install the top ring.
INSTALLATION OF PISTON ASSEMBLY

Install the connecting rod bearing to both the connecting rod and connecting rod cap. 5 Check that the protruding portion on top of the connecting rod bearing is in the groove in the rod and connecting rod cap. The connecting rod bearing has a mark on the rear side showing the standard (STD) or oversize (OS) thickness. 5 When installing used connecting rod bearings, install each bearing to its original position. Caution: Do not coat the rear face of the connecting rod bearing shell with lubricant. Caution: Do not let dirt get into the lubricating oil. If the lubricating oil is dirty, there will be premature wear of the connecting rod bearing. Coat the connecting rod bearing with Lubriplate 105 so that a thin film forms.
Coat the piston ring and piston skirt with clean 15W40 engine oil.
13-56
114 SERIES
ASSEMBLY OF ENGINE
Position the piston rings. 5 For details of the installation of the rings to the piston, see INSTALLATION OF PISTON RING.
Piston ring compressing tool (Part No. 3823290) Using a piston ring compressing tool, compress the piston ring.
Using a clean cloth which does not leave threads, clean the crankshaft bearing journal.
Using a clean cloth which does not leave threads, wipe the cylinder bore. Coat the cylinder bore with clean 15W-40 engine oil.
114 SERIES
13-57
ASSEMBLY OF ENGINE
Engine crankshaft rotation tool (Part No. 3377371) Rotate the crankshaft so that the connecting rod journal of the piston to be installed is at bottom dead center (BDC).
Caution: Set so that the FRONT mark on the piston and the numbers on the connecting rod and connecting rod cap face in the direction shown in the diagram.
Caution: When installing the piston and connecting rod, be careful not to damage the cylinder bore. Install the piston and connecting rod assembly to the cylinder bore so that the FRONT mark on the piston is at the front of the cylinder block. Hold the piston ring compressing tool in contact with the cylinder liner. Pass the piston ring compressing tool through and push the piston inside the cylinder liner. 5 If the piston does not move freely, remove the piston and check that the piston ring is not broken or damaged. Push the piston into the bore so that the tip of the piston is approx. 50 mm lower than the tip of the bore. Next, pull the connecting rod at the top of the crankshaft journal.
13-58
114 SERIES
ASSEMBLY OF ENGINE
Coat the thread of the connecting rod mounting bolts with clean 15W-40 engine oil.
Make sure that the numbers on the connecting rod and connecting rod cap are the same. When installing the connecting rod cap, the protruding portion and groove of the connecting rod cap must be on the same side as the protruding portion and groove of the connecting rod. Coat the inside of the connecting rod bearing with Lubriplate 105 or equivalent. Install the connecting rod bearing to the connecting rod cap. Install the connecting rod cap and start to tighten the connecting rod nut.
Coat the connecting rod nut with clean 15W-40 engine oil.
19 mm Tighten the connecting rod nuts in turn and pull in the connecting rod cap to the specified position.
114 SERIES
13-59
ASSEMBLY OF ENGINE
19 mm socket, torque wrench Tighten the connecting rod cap nuts. Tighten the two mounting bolts in turn. Step 1 2 3 Torque 40 Nm {4.1 kgm} 80 Nm {8.2 kgm} 120 Nm {12.2 kgm}
After tightening, move the connecting rod and check the side clearance.
Measure the side clearance between the connecting rod and crankshaft. Limit of connecting rod side clearance mm Min. 0.10 Max. 0.33
The crankshaft must rotate freely. Check that the rotation is free with the connecting rod cap installed. If the camshaft does not rotate freely, check the installation of the connecting rod bearing and the bearing size.
13-60
114 SERIES
ASSEMBLY OF ENGINE
INSTALLATION OF GEAR HOUSING

If they have been removed, install the 2 gear housing dowel pins. 5 Fit the tapered end of the dowel exactly in the cylinder block.Install the pin in the bottom of the hole.
Install the gear housing gasket.
15 mm If there is any damage to the stud of the fuel injection pump or it is installed to a new housing, coat the thread with Loctite 242, remove the double nut, then install.
Small chisel and hammer When replacing the gear housing, remove the engine nameplate and install the new gear housing.
114 SERIES
13-61
ASSEMBLY OF ENGINE
13 mm Caution: When installing a new gear housing or any part other than the original gear housing, the timing pin assembly must be arranged correctly. For details, see INSTALLATION OF TIMING PIN ASSEMBLY in this section. Install the gear housing and mounting bolts.
3 Mounting bolt:
M8: M12:
24 Nm {2.4 kgm} 60 Nm {6.1 kgm}
Using the oil pan rail, trim the gear housing gasket uniformly. 5 Be careful not to let the trimmed portion of the gasket fall inside the engine.
INSTALLATION OF OIL PUMP

Coat the oil pump with clean 15W-40 engine oil. 5 When installing, if the oil pump is filled with oil, the oil can be sucked in quickly when the engine is started.
Check that the oil pump idler gear pin is installed in the mounting hole in the cylinder block.
13-62
114 SERIES
ASSEMBLY OF ENGINE
Seat the oil pump back plate at the bottom of the cylinder block hole. If the pump is correctly installed, the pump flange will not contact the cylinder block.
13 mm Tighten the oil pump mounting bolts order shown in the diagram. Tighten the mounting bolts as follows. Step 1 2 Torque 5 Nm {0.51 kgm} 24 Nm {2.5 kgm} in the
Use the dial gauge on the magnet base to measure the backlash of the idler gear.
Measure the backlash of the gear. 5 When measuring the backlash, if the connecting gears are not held in position and prevented from moving, the measurement will be the total for both gears. Limit for backlash (A & B) of oil pump and idler gear mm Min. 0.08 Max. 0.33
114 SERIES
13-63
ASSEMBLY OF ENGINE
INSTALLATION OF CAMSHAFT
Coat the camshaft bore with Lubriplate 105. 5 For details of the installation of the camshaft bushing, see REBUILDING AND REPLACING, Installation of camshaft bushing. Hint for maintenance: When installing the crankshaft at the bottom dead center (B, C, D) of the No. 1 cylinder, the camshaft does not contact the camshaft counterweight.
Coat the camshaft journal, protruding portion, and thrust plate with Lubriplate 105.
Install the camshaft and gear assembly in the cylinder block up to the final journal.
Align the timing mark on the camshaft with the timing mark on the crankshaft.
13-64
114 SERIES
ASSEMBLY OF ENGINE
Caution: If the engine is perpendicular, there is no danger of dropping the camshaft assembly on your fingers when installing the thrust plate.
13 mm Push the camshaft into the cylinder block. Install the thrust plate mounting bolts.
3 Mounting bolt: 24 Nm {2.4 kgm}
Measuring camshaft end play 5 The end clearance is determined by the thickness of the thrust plate and the groove of the camshaft. Limit(A)for camshaft end play mm Min. 0.12 Max. 0.34
If the gear has been replaced, check that the backlash is correct. Measuring camshaft gear backlash Limit for camshaft backlash mm Min. 0.08 Max. 0.33
114 SERIES
13-65
ASSEMBLY OF ENGINE
INSTALLATION OF WATER PUMP

13 mm Install the O-ring to the water pump mount groove. Position the water pump assembly on the pump mount. Align the mounting holes and install 2 mounting bolts at the 11 o'clock and 4 o'clock positions. 5 The mounting bolt at the 7 o'clock position is longer, and it is also used to tighten the alternator mounting bracket.
INSTALLATION OF OIL SUCTION TUBE

Position the new oil suction tube gasket on the cylinder block. Check that the gasket is correctly aligned with the oil suction hole inside the cylinder block.
8 mm Set the oil suction tube on top of the gasket, and align with the mounting holes. Tighten the mounting bolts as follows. Step 1 2 3 Position Suction tube and block A Brace and block B Brace and suction tube C Torque 9 Nm {0.9 kgm} 9 Nm {0.9 kgm} 9 Nm {0.9 kgm}
INSTALLATION OF REAR CRANKSHAFT SEAL

Use a special cloth to remove the rust and accumulated dirt on the crankshaft flange. Use a clean cloth to clean the rear crankshaft flange.
13-66
114 SERIES
ASSEMBLY OF ENGINE
Check visually that there is no wear in the seal contact area. If there is any deep groove in the seal contact area with a depth similar to scratch marks made by fingernails or sharp objects, it is necessary to install a wear sleeve to the seal surface. See the following procedure for details.
INSTALLATION OF WEAR SLEEVE, REAR CRANKSHAFT SEAL

Hammer, chisel If a wear sleeve is installed to the crankshaft, remove the old wear sleeve before installing the new wear sleeve. Caution: Do not make any dents or protrusions in the crankshaft with the chisel. If the crankshaft is damaged, replace it. Use a cold chisel of the same width as the wear sleeve. Tap once or twice with the hammer to make a mark with the cold chisel on the wear sleeve. When this is done, the wear sleeve will expand and the sleeve can be removed. 5 Because of the equipment, crankshaft rear oil seal (A) and wear sleeve (B) are combined into a replacement kit and are installed to the crankshaft as an assembly. Do not remove the crankshaft rear oil seal from the wear sleeve of the crankshaft rear seal.
Install the rear cover and the gasket. 5 Install the rear cover mounting bolts. Do not tighten them when doing this. When installing the oil pan, loosen the oil pan mounting bolts and ensure the rear cover clearance and gasket clearance. 5 Align the seal with the rear cover and install it correctly. After installing the seal, to prevent any irregularity in the seal lip, do not push the cover in any direction or apply any force.
114 SERIES
13-67
ASSEMBLY OF ENGINE
To lubricate the oil seal when installing, it is necessary to coat the outside diameter of the seal case with low-stimulant soap.
Using the maintenance to (Part No. 3824078), install the oil seal and wear sleeve assembly. Install the two threaded studs in the crankshaft bolt holes. Coat the crankshaft, threaded studs, crankshaft rear seal, and inside diameter of the wear sleeve installation tool with a small amount of clean 15W-40 engine oil.
Position chamfered tip (A) of the wear sleeve on tip (B) of the crankshaft. Position the counterbore end (C) of the installation tool on top of the stud, then align the wear sleeve so that it is perpendicular to the end face of the camshaft. Install washer (D) and nut (E) to the threaded stud. Tighten the nuts in turn until the installation tool contacts the tip of the crankshaft.
3 Nut: 20 Nm {2.0 kgm}
Do not tighten any nut more than 1/2 turns in order to prevent the wear sleeve from tightening and having irregular elongation.
Remove the installation tool and threaded stud.
13-68
114 SERIES
ASSEMBLY OF ENGINE
To lubricate the oil seal when installing, it is necessary to coat the outside diameter of the seal case with low-stimulant soap.
Hammer, seal installation tool Install the seal to the rear cover. Using the installation tool and hammer, push the seal into the rear cover until the outside diameter of the seal installation tool contacts the rear cover. 5 Do not remove the crankshaft seal pilot tool.
When installing the seal, do not use any type of lubricant on the crankshaft. Coat the seal lip with lubricating oil and make sure that the crankshaft is clean and dry before installing it. Install 2 guide pins (M6 x 1.00 x 50 mm) 180 apart to the rear of the cylinder block. Install the seal, then install the rear cover and gasket to the guide pins.
8 mm Using the alignment tool provided in the seal kit, center the rear cover and crankshaft. Always set the rear cover so that both sides of the oil pan rail on top of the cylinder block are uniform.
114 SERIES
13-69
ASSEMBLY OF ENGINE
Remove the guide pins. Install the rear cover mounting bolts and tighten them.
Remove the rear crankshaft seal pilot tool.
Using the oil pan rail, trim the gear housing gasket uniformly. 5 Be careful not to let the trimmed portion of the gasket fall inside the engine.
INSTALLATION OF OIL PAN

Be sure to fill the joints between the oil pan rail, gear housing and rear seal housing with 2 mm bead of Three Bond sealant, Cummins Part No.3823494. 5 The lubricating oil pan should be assembled and the capscrews torqued within 15 minutes after applying the sealant.
Coat both sides of the new oil pan gasket with a 2 mm bead of Three Bond sealant (Part No. 3823494). Install the gasket. Install the oil pan.
13-70
114 SERIES
ASSEMBLY OF ENGINE
10 mm Assemble the oil pan and mounting bolts as shown in the diagram. Tighten all the mounting bolts in the order shown in the diagram.
17 mm Install the drain plug and a new sealing washer.
3 Drain plug: 80 Nm {8.2 kgm}
INSTALLATION OF TIMING PIN ASSEMBLY

Caution: Timing pin assembly (2) is accurately positioned on gear housing (4) at the top dead center (T.D.C) of the No. 1 cylinder. When installing gear housing (4), if it is not the original component, timing pin assembly (2) must be positioned again. If timing pin assembly (2) is not positioned at the top dead center (T.D.C) of the cylinder, the fuel injection timing will not be correct. 13 mm, 18 mm Rotate the engine on the engine stand and set it to a horizontal position. To position the timing pin assembly again, temporarily install the vibration damper and No. 16 gauge wire pointer. Insert a flat washer between the pointer and the gear housing to prevent damage to the gear housing.
114 SERIES
13-71
ASSEMBLY OF ENGINE
19 mm, cylinder liner clamp set (Part No. 3822503) Assemble 2 cylinder liner clamp sets on top of the No. 1 cylinder bore. Tighten the cylinder liner clamps.
3 Clamp mounting bolt: 68 Nm {6.9 kgm}
Position the 2 flat washers on top of the piston so that the 2 washers contact the cylinder clamps.
Rotate the crankshaft in a clockwise direction until the washers on top of the piston contact the cylinder liner clamps. Make a mark on the vibration damper next to the pointer.
Rotate the crankshaft in a counterclockwise direction until the washers on top of the piston contact the cylinder liner clamps. Make a mark on the vibration damper next to the pointer.
13-72
114 SERIES
ASSEMBLY OF ENGINE
Make a mark midway between the two pointer marks on the vibration damper. This mark indicates the top dead center (T.D.C).
19 mm Remove the cylinder liner clamp and washer. Rotate the crankshaft in the normal direction of rotation until the pointer is aligned with the top dead center (T.D.C) mark.
Find the timing pin hole in the camshaft gear from the rear face of the camshaft gear housing. If the hole cannot be seen, rotate the crankshaft one more turn.
Coat the O-ring with clean 15W-40 engine oil, then install it to the timing pin groove. Install the timing pin assembly.
114 SERIES
13-73
ASSEMBLY OF ENGINE
T-25 trick Push the timing pin into the hole in the camshaft gear so that the center of the housing is aligned. Keep the timing pin inserted while the timing pin assembly trick bolts are being tightened.
3 Tightening torque: 8 Nm {0.8 kgm}
When the timing pin assembly bolt has been tightened, check that the timing pin has not come out from the camshaft gear hole.
13 mm, 18 mm Caution: To prevent damage to the pin and gear, always remove the timing pin before rotating the crankshaft. Remove the vibration damper and pointer.
INSTALLATION OF FLYWHEEL HOUSING

Dry-type clutch Install 2 dowel pins at the rear of the cylinder block. Knock in the dowel pin until it contacts the bottom of the hole.
To align the position and the support of the flywheel, insert 2 guide pins (M12 x 1.75 x 100 mm) to the cylinder block. 5 For the dry-type clutch, a seal ring is necessary on top of the rear seal housing. Install the seal to the machined face of the rear seal housing, then coat with Lubriplate 105.
13-74
114 SERIES
ASSEMBLY OF ENGINE
Check visually that the rear face of the mounting surface of the cylinder block and flywheel housing is clean, and that there are no dents or flashes.
Install the flywheel housing. Position the flywheel housing with the alignment dowel and the guide pin. 5 When installing, be careful not to damage the seal ring. Remove the two guide pins (M12 x 1.75 x 100 mm).
15 mm Install the flywheel housing mounting bolts and tighten in the order - shown in the diagram.
TESTING COAXIALITY OF FLYWHEEL HOUSING BORE

Dial gauge attachment (part No. ST-1325) Install the dial gauge to the crankshaft. Hold the dial gauge with the extension bar and install so that the dial indicator does not bend. If the extension bar bends or the dial gauge slips, the measurement cannot be read accurately. Align the dial gauge with the 6 o'clock position and set the gauge indicator to 0.
114 SERIES
13-75
ASSEMBLY OF ENGINE
Engine crankshaft rotating tool (part No. 3377371) Rotate the crankshaft slowly. Record the values obtained at the 9 o'clock, 12 o'clock, and 3 o'clock (A, B, C) positions and record them on the coaxiality record sheet. Check the 0 point again at the six o'clock position. The values at A, B, and C are positive or negative values. When recording these values, see the appended diagram and judge whether they are positive or negative values.
Rotate the crankshaft until the dial gauge reaches the 12 o'clock position, then set the gauge to 0. 5 Do not apply force to the crankshaft until it exceeds the bearing clearance. Do not put a lever in contact with the flywheel housing. If these things are done, it becomes impossible to read the bearing clearance accurately. At this point, raise the rear of the crankshaft fully. Record this on the coaxiality record sheet as the value for (d). This is the adjustment of the perpendicular bearing clearance, and it is always a positive value. Using the coaxiality work sheet, judge the values for overall perpendicular and overall horizontal. "Overall horizontal" is equal to measurement (a) at 9 o'clock - measurement (c) at 3 o'clock. "Overall vertical one" is equal to measurement (b) at 12 o'clock + bearing clearance (d). Example:6 o'clock = standard = 0.000 mm 9 o'clock = (a) = 0.102 mm 12 o'clock = (b) = 0.076 mm 3 o'clock = (c) = -0.051 mm If the numbers from the example of the record sheet above are used, "Overall horizontal" = 0.152 mm and "Overall vertical" = 0.127 mm. Mark the value for "Overall horizontal" on the horizontal axis in the chart and the value for "Overall vertical" of the vertical axis in the chart. Using a ruler, find the point where the "Overall horizontal" value and "Overall vertical" value intersect. For the coaxiality of the flywheel housing to be within the range for the specification, the intersection must be within the shaded area. If the values for "Overall horizontal" and "Overall vertical" calculated from the example above are used, the intersection is inside the range of the shaded area. Therefore, the coaxiality of the flywheel housing is within the specified range.
13-76
114 SERIES
ASSEMBLY OF ENGINE
If the intersection is not within the range of the shaded area, remove the dowel pin and install the housing again. 5 The ring dowel is not necessary to maintain the coaxiality of the housing. Support the flywheel housing at the specified position with the fixed force of the bolt. After discarding the dowel pin, install the flywheel housing to the engine. When positioning the housing, tighten the bolts enough to support the flywheel housing in the specified position, but tap it with a wooden hammer to give it enough looseness to move slightly. After completing the above procedure, check the coaxiality again. Install the flywheel housing mounting bolts and tighten in the order - shown in the diagram.
Wet-type clutch Follow all the steps needed for installing the dry-type clutch, then add the following items.
Coat the flywheel housing drain plug with pipe sealant, then install in the hole at the bottom of the flywheel housing. Tighten the drain plug. If the plug size is different, see the pipe tightening torque in the Foreword.
114 SERIES
13-77
ASSEMBLY OF ENGINE
Install the plastic plug in the tachometer drive access hole.
13 mm Install the access plate and new access plate gasket. Install the access plate mounting bolts and tighten.
Clean the flywheel housing and cylinder block mounting surfaces completely. Wash these surfaces. There must be no oil or accumulated dirt on them.
The center bolt hole on the flywheel housing mounting pad passes right through. Coat the stop screw with Loctite 277 and install it in the hole. Limit for stopper bolt mounting depth mm Min. 0.00 Max. 3.0
13-78
114 SERIES
ASSEMBLY OF ENGINE
Coat the area around all the bolts on the flywheel housing mounting surface with a continuous bead of Three Bond sealant.
Coat the thread of the mounting bolts with Loctite 277. Install the mounting bolts and tighten them. The order for tightening the bolts is the same as for the dry clutch.
INSTALLATION OF FLYWHEEL
5 Use a new pilot bearing when installing a new or rebuilt clutch. Use a mandrel and a hammer to remove the pilot bearing. Use a Scoth-Brite 7448, or equivalent, to clean the pilot bore.
Use a mandrel and hammer to install the pilot bearing. 5 The pilot bearing must be installed even with the pilot bore surface. For details of replacing the flywheel ring gear, see TESTING AND ADJUSTING, Flywheel housing and flywheel.
114 SERIES
13-79
ASSEMBLY OF ENGINE
Remove 2 guide pins (M12 x 1.25 x 90mm) at a 180 interval and install to the crankshaft flange. 5 For machines fitted with a clutch, the threads of the mounting bolt hole for the clutch pressure plate are metric or standard parts. Always use the correct bolts. Measure the size and design of the thread of the mounting bolts, then install 2 T-handles at point and point of the flywheel.
Check visually that the rear surface of the crankshaft and flywheel mounting flange are clean and that there are no dents or flashes. 5 The weight of the component is more than 23 kg. When installing the flywheel, use a hoist or ask another worker for assistance. Install the flywheel to the guide pin.
Coat the surface of the washer and the thread of the flywheel mounting bolts with clean 15W-40 engine oil.
Install 6 flywheel mounting bolts. Remove the T-handle from the guide pin, then install the remaining flywheel mounting bolts in the holes from which the guide pins were removed.
13-80
114 SERIES
ASSEMBLY OF ENGINE
19 mm socket, torque wrench, engine crankshaft rotation tool (Part No. 3377371) When tightening the flywheel mounting bolts, make sure that the crankshaft does not rotate. Tighten the flywheel mounting bolts in the order given in the diagram.
MEASURING RUNOUT OF FLYWHEEL BORE

Using dial gauge (Part No. 3376050) or equivalent and dial gauge attachment (Part No. ST1325), check the runout of flywheel bore and surface . Install the attachment to the flywheel housing. Install the dial gauge to the attachment. Put the tip of the dial gauge in contact with the inside diameter of the flywheel bore, then set the dial gauge indicator to 0. Using the engine crankshaft rotation tool (Part No. 3377371), rotate the crankshaft one full turn (360). 5 The total indicator reading (TIR) of the dial gauge must not exceed 0.20 mm.
If the TIR exceeds the standard range, do as follows. Remove the flywheel.
114 SERIES
13-81
ASSEMBLY OF ENGINE
Check that there is no dirt or damage to the flywheel mounting surface.
Check that there is no dirt or damage to the crankshaft.
Install the flywheel and inspect the runout of the flywheel bore again.
If the runout of the flywheel bore does not fulfill the standard, replace the flywheel.
13-82
114 SERIES
ASSEMBLY OF ENGINE
MEASURING FACE RUNOUT OF FLYWHEEL

Put the contact tip of the dial gauge in contact with the flywheel surface at a point as close as possible to the outside diameter, then check the runout of face . 5 Push the flywheel towards the front to remove the end clearance from the crankshaft. Adjust the dial gauge so that the dial gauge indicator points to 0.
Using the engine crankshaft rotation tool (Part No. 3377371), rotate the crankshaft one full turn. Measure the runout of the flywheel at 4 equal points around the flywheel. 5 Each time you measure the point, push the flywheel towards the front of the engine to remove the end clearance of the crankshaft.
The total indicator reading (TIR) of the dial gauge must not exceed the following standard. The flywheel radius (A) mm 203 254 305 356 406 Max. flywheel surface TIR mm 0.203 0.254 0.305 0.356 0.406
If the face runout of the flywheel is not within the standard range, remove the flywheel. Check between the flywheel mounting surface and the crankshaft flange to see that there are no dents, dirt, or foreign material.
114 SERIES
13-83
ASSEMBLY OF ENGINE
INSTALLATION OF STARTING MOTOR

Wet-type housing If there is any spacer at the starting motor mounting surface, coat the starting motor gasket and both faces of the spacer and the starting motor gasket with Three Bond sealant.
12 mm Coat the starting motor mounting bolts with Loctite pipe sealant PST. Install the starting motor. Tighten the starting motor mounting bolts.
INSTALLATION OF OIL COOLER

Install 2 guide pins (M8 x 1.25 x 80 mm) to the cylinder block. Assemble the guide pin cooler gasket, oil cooler, and oil cooler cover gasket. 5 When installing a new element, always remove the transportation plug. Install 9 mounting bolts.
10 mm Remove the 2 guide pins, then install the remaining 2 mounting bolts. Tighten all the mounting bolts of the oil cooler and filter head.
13-84
114 SERIES
ASSEMBLY OF ENGINE
INSTALLATION OF OIL FILTER

Before installing the oil filter, coat the gasket seal surface with clean 15W-40 engine oil. 5 The filter must be installed within 15 minutes after coating the rubber seal with oil. Fill the oil filter with clean 15W-40 engine oil.
Caution: If the oil filter is tightened to an excessive torque, the thread will be deformed and the filter element seal will be broken. Install the filter according to the procedure specified in the Operating and Maintenance Manual.
INSTALLATION OF CYLINDER HEAD

The cylinder block and the cylinder head must be clean and dry. 5 In the case of the standard head gasket, the largest permissible piston protrusion from the top surface of the block is 0.40 mm. If the piston protrusion is more than the specified amount, use a thin head gasket. 5 Check that the gasket is properly aligned with the cylinder block holes.
Position the gasket with dowels. 5 The weight of the component is more than 23 kg. When installing the cylinder head, use a hoist. Caution: Do not drop the cylinder head on top of the cylinder head gasket. The gasket material will be damaged. Install the cylinder head to the gasket and the cylinder block. Check that the cylinder head is installed to the dowels inside the cylinder block.
114 SERIES
13-85
ASSEMBLY OF ENGINE
Coat the thread of the cylinder head mounting bolts and the bottom of the head flange with clean 15W40 engine oil. It is covered by the head cover, so do not align the bolts with the painted head in the center when installing. Before installing, remove the excess oil from the bolt thread.
Install the bolts inside the cylinder head. 5 There are six mounting bolts installed around the injector hole.
The cylinder head mounting bolts can be distinguished by the angle mark on the tip. Follow the procedure in the explanation below and tighten the cylinder head mounting bolts according to the 3 time "torque + angle" method.
1. Tighten all the mounting bolts in the order shown in the diagram.
3 Head bolt: (1st time) 70 Nm {7.1 kgm)
Follow the numbered procedure and check the torque of all the mounting bolts again.
13-86
114 SERIES
ASSEMBLY OF ENGINE
2. Tighten 14 long mounting bolts according to the numbered order shown in the diagram.
3 Head bolt: (2nd time) 145 Nm {14.8 kgm}
Follow the numbered procedure and check the torque of all the long mounting bolts again.
3. Tighten all the mounting bolts by the angle method according to the numbered order shown in the diagram as shown on the mounting bolt head. 3 Head bolt: (3rd time) Tighten 90
To turn the mounting bolts correctly to the specified angle, make small dot and window marks on the mounting bolt head.
Make marks on the cylinder head neighboring the dot on the mounting bolt head. This mark helps by acting as an index.
114 SERIES
13-87
ASSEMBLY OF ENGINE
Turn the bolts until the mark made on the cylinder head enters the range of the window on the bolt head.
Hints for maintenance: Using a permanent marker, make a mark on one socket at the position corresponding to the flat face angle of the hexagonal socket.
After completing the tightening, make a mark on the cylinder head at the position of the dot.
Determine the position of the bolt socket so that the mark on top of the socket becomes the same point as the window on the bolts.
13-88
114 SERIES
ASSEMBLY OF ENGINE
Turn the socket until the mark on the socket is aligned with the mark on the cylinder head.
INSTALLATION OF PUSH ROD

Check that the push rod is not bent.
Install the push rod to the socket of the tappet where the push rod was removed. Coat the push rod socket and the valve stem with clean 15W-40 engine oil.
ASSEMBLY OF ROCKER LEVER AND SHAFT

Install the adjustment screw and locknut.
114 SERIES
13-89
ASSEMBLY OF ENGINE
Install the retainer, thrust washer, and wave-shaped spring washer as shown in the diagram.
Coat the shaft with clean 15W-40 engine oil.
Position the lever to the rocker shaft.
Install the remaining wave-shaped spring washers, thrust washers, and retainers as shown in the diagram.
13-90
114 SERIES
ASSEMBLY OF ENGINE
Compress the wave-shaped spring washer and install it to the bottom half of the stand as shown in the diagram.
INSTALLATION OF ROCKER LEVER ASSEMBLY

Check that the rocker lever adjustment screw is returned fully to the top position.
Install the support and rocker lever assembly to the rocker lever oil manifold. 5 Check that the dowels of the stand are installed inside the dowel holes.
Lubricate the head side and the threads of the bolts of the stand with 15W-40 engine oil. Install the retaining clamps and bolts.
114 SERIES
13-91
ASSEMBLY OF ENGINE
10 mm Caution: To prevent damage to the rocker lever or push rod, check that the adjustment screw ball inside the push rod socket is positioned when tightening. Caution: If the engine oil carry-over is excessive, rotate the rocker lever shaft in the direction of the engine push rod (clockwise as seen when facing the front of the engine). This reduces the overhead oil. Tighten the lock clamp bolt.
3 Lock clamp bolt: 55 Nm {5.6 kgm}

1/2 inch screwdriver, engine crankshaft rotation tool (Part No. 3377371) Push engine timing pin (2), rotate the crankshaft slowly, and look for the No. 1 cylinder top dead center (T.D.C) position.
Caution: To prevent damage to the timing pin, always remove the timing pin after finding the top dead center.
13-92
114 SERIES
ASSEMBLY OF ENGINE
Thickness gauge Adjust the valve clearance when the engine is cool (below 60C). Caution: Insert the thickness gauge between the valve stem and rocker lever and adjust the clearance so that it is a sliding fit. Clearance between valve steam and rocker lever Intake valve Exaust valve 0.30mm 0.61mm Valve arrangement Starting from the front of the cylinder head, the No. 1 valve is the intake valve and the No. 2 valve is the exhaust valve. The position is determined in the same direction for all the cylinders.
14 mm, flat-headed screwdriver Locate the No. 1 cylinder top dead center (T.D.C). Adjust the valves marked X in the chart. Tighten the locknuts.
3 Locknut: 24 Nm {2.4 kgm}
Check the valve clearance again.
Make a mark on the end face of the crankshaft or flywheel. Rotate the crankshaft 360. 5 Always remove the timing pin.
114 SERIES
13-93
ASSEMBLY OF ENGINE
14 mm, flat-headed screwdriver Adjust the valves marked X in the chart. Tighten the locknuts.
3 Locknut: 24 Nm {2.4 kgm}
Check the valve clearance again.
INSTALLATION OF HEAD COVER

Fit the rubber seal in the head cover groove. Start installation from the overlap area marked in the diagram. Do not pull or extend the rubber seal. If the seal overlaps more than shown in the diagram, cut off the excessive parts so that the overlap is suitable.
Install a new seal O-ring to the head cover mounting bolt. 5 For engine is equipped with a Westgate turbocharger, a stud bolt must be installed in the 3rd hole from the front. This is for the Westgate actuator hose clamp.
15 mm Install the valve cover mounting bolts and tighten in the order as shown in the diagram.
13-94
114 SERIES
ASSEMBLY OF ENGINE
INSTALLATION OF CYLINDER BLOCK BREATHER TUBE

13 mm, 18 mm Install the hose clamp to the breather tube. Tighten the bolt for the breather tube support bracket.
3 Mounting bolt:
A: 24 Nm {2.4 kgm} B: 43 Nm {4.4 kgm}
INSTALLATION OF INJECTOR
Coat the seal lip of the sleeve with anti-seize compound. Assemble the injector, seal sleeve, new copper seal washer, and lock clamp. 5 Use only one washer. Hint for maintenance: If the area between the washer and the injector is coated thinly with 15W-40 engine oil, it is easier to keep the washer in position when installing. Install the injector assembly inside the injector bore.The injector return connector must be facing the head cover.
13 mm Install the lock mounting bolt.

114 SERIES
13-95
ASSEMBLY OF ENGINE
INSTALLATION OF FUEL DRAIN MANIFOLD

10 mm Install the fuel drain manifold and new copper seal washer as shown in the diagram.
Install the banjo connector seal (Y-shaped water feed port washer) as shown in the diagram.
10 mm Install a new seal washer and connect the drain manifold to the fuel filter head. Filter head I-joint :15 Nm {1.5 kgm} Injector I-joint :9 Nm {0.9 kgm}
3 Mounting bolt:
INSTALLATION OF ENGINE LIFTING BRACKET

18 mm Install the front bracket to the front exhaust manifold on the cylinder head. Install the rear bracket to the rear of the cylinder head. Tighten the mounting bolts.
INSTALLATION OF INTAKE MANIFOLD COVER

Install the manifold cover and the gasket. Do not install the bolts in the holes used to secure the highpressure fuel line support bracket.
13-96
114 SERIES
ASSEMBLY OF ENGINE
INSTALLATON OF AFTERCOOLER
If the machine is equipped with an aftercooler, install the aftercooler, gasket, and mounting bolts. 5 Coat both sides of the aftercooler gasket with Three Bond. Do not install bolts in the holes used for securing the high-pressure fuel line support gasket.
8 mm Install the coolant supply tube and coolant return tube . Install the air crossover tube.
INSTALLATON OF EXHAUST MANIFOLD

Assemble the exhaust manifold mounting bolts and gaskets in sets to the manifold. Apply Anti-seize compound to the mounting bolts. 5 The bead of the exhaust manifold gasket can be installed in either direction. The tab in the gasket hole is provided to make it possible to hold the gasket in the specified position when installing.
16 mm Install the exhaust manifold and gasket. Tighten the bolts in the order shown in the diagram.
After the capscrews are tightened to the correct torque value, bend over the lockplates to prevent the capscrews from loosening.
114 SERIES
13-97
ASSEMBLY OF ENGINE
INSTALLATION OF TURBOCHARGER
Before using the turbocharger mounting studs, coat them with high-temperature anti-seize compound. When installing them, coat the stud thread with nickelbased high-temperature anti-seize compound.
Install the studs and use double nuts.

3 Stud bolt: 10 Nm {1.0 kgm}
15 mm Install the gasket with raised bead to the exhaust manifold.

Install the turbocharger.
13 mm 5 The turbocharger center bearing and compressor outlet port must be installed facing in the correct direction. To face the center bearing housing in the correct direction, bend the lock plate, loosen the turbine housing mounting bolt, then position the bearing housing.
13-98
114 SERIES
ASSEMBLY OF ENGINE
INSTALLATION OF TURBOCHARGER OIL DRAIN TUBE

Coat the area around the end of the flange and bottom drain tube with Loctite 227. Using a tube driver and hammer, tap the center of the bore to knock the tube in until the flange contacts the cylinder block. Check that the end of the tube is at the 12 o'clock position. 5 If the tube driver cannot be used, it is possible to use a 22 mm wrench as shown in the diagram.
13 mm Tighten the hose and clamp lightly to the turbocharger drain tube. Install the drain tube and gasket to the turbocharger.
3 Clamp: 5 Nm {0.5 kgm}
Position the turbocharger drain hose, connect to the drain tube, then tighten the clamps.
13 mm, punch, hammer If they are loose, tighten the turbine housing mounting bolts. Then bend the lock plate to a flat surface to prevent it from coming loose.
114 SERIES
13-99
ASSEMBLY OF ENGINE
7/16 inch, 10 mm If necessary loosen the V-band clamp of the compressor housing, and align the housing with the center of the air crossover tube. 5 For the turbocharger with Westgate actuator, do not use force to move the housing when setting the compressor outlet port to face the correct direction. This will damage the actuator bracket and also damage the internal parts of the turbocharger.
Snap ring pliers For the turbocharger with snap ring, loosen the snap ring, then use snap ring pliers or channel lock to align the turbocharger air outlet port connector and the compressor housing.
7/16 inch, plastic hammer Loosen the 2 bolts holding the actuator bracket brace to the V-band clamp. When it is facing in the correct direction, loosen the V-band clamp nut, tap the area around the V-band clamp with a plastic hammer, then tighten the 2 bolts on the brace.
3 V-band clamp nut: 8 Nm {0.8 kgm} 3 Mounting bolt of actuator bracket brace:
13 Nm {1.3 kgm}
Lubricate the turbocharger. Add 50-60 cc of clean oil through the oil inlet port fitting at the top of the turbocharger and rotate the turbocharger impeller to send oil to the bearing.
13-100
114 SERIES
ASSEMBLY OF ENGINE
INSTALLATION OF TURBOCHARGER OIL SUPPLY HOSE

16 mm crowfoot, 19 mm socket Coat the adapter joint O-ring with vegetable oil. Install the joint to the end of the turbocharger bearing housing and oil filter head, then tighten the joint.
3 Joint bolt: 24 Nm {2.4 kgm} 3 Joint bolt: 35 Nm {3.6 kgm}
Install the oil supply line.
INSTALLATION OF TURBOCHARGER EXHAUST OUTLET PORT CONNECTOR

Install the exhaust outlet port connector. 5
3 Band clamp : 8 Nm {0.8 kgm}
Do not tighten the 2 mounting bolts until the band clamp is tightened.
INSTALLATION OF CROSSOVER
Screwdriver Install the crossover and clamp, then tighten.
Make the clearance between the compressor outlet port and the crossover at least 9.5 mm.
INSTALLATION OF THERMOSTAT AND HOUSING

Install 2 thermostats inside the bore as shown in the diagram.
114 SERIES
13-101
ASSEMBLY OF ENGINE
Install a new gasket and thermostat. Two mounting bolts are used to install, but do not tighten them until the coolant outlet connector is installed.
INSTALLATION OF COOLANT OUTLET CONNECTOR

10 mm Install the new gasket and coolant outlet connector. Install the thermostat housing and coolant connector mounting bolts, then tighten.
INSTALLATION OF COOLANT AIR BLEED JOINT

9/16 inch Coat the threads with pipe sealant using Teflon, then install the 1/8 inch coolant air bleed joint. Tighten the joint and set it to face in the correct direction so that the valve hole is at the 12 o'clock position.
3 Joint: 8 Nm {0.8 kgm}
INSTALLATION OF COOLANT AIR BLEED VALVE

9/16 inch Coat the thread with pipe sealant using Teflon, then install the air bleed valve.
3 Cock: 5 Nm {0.5 kgm}
13-102
114 SERIES
ASSEMBLY OF ENGINE
INSTALLATION OF COOLANT AIR BLEED TUBE

7/16 inch Coat the thread with Teflon, then install the coolant air bleed tube. Tighten the joint.
3 Joint bolt: 8 Nm {0.8 kgm}
INSTALLATION OF COOLANT INLET CONNECTOR

Install a new coolant inlet connector, then tighten the clamp.
After installing the engine to the machine, it is necessary to carry out final positioning of the inlet connector.
INSTALLATION OF ALTERNATOR BRACKET

13 mm Assemble the alternator bracket to the thermostat housing.
INSTALLATION OF ALTERNATOR
Position the alternator on the bracket, then tighten the mounting bolts. 5 5 Set the alternator on the bracket, and secure with the mounting bolts and spacers. Do not tighten at this point.
114 SERIES
13-103
ASSEMBLY OF ENGINE
INSTALLATION OF ALTERNATOR BRACE

13 mm Install the mounting bolts to the alternator mounting bracket and water pump. Tighten the mounting bolts with your fingers.
Caution: To make the belt alignment correct, check that the alternator brace is in a suitable position. Connect the alternator mounting bracket to the alternator. Tighten the mounting bolts by hand.
Tighten the water pump mounting bolts.
15mm, 18mm, 19mm

3 Mounting bolt:
Tighten the alternator mounting bolts. A: 43 Nm {4.4 kgm} B: 24 Nm {2.4 kgm} C: 80 Nm {8.2 kgm}
13-104
114 SERIES
ASSEMBLY OF ENGINE
INSTALLATION OF BELT TENSIONER BRACKET

5 mm hexagonal wrench Install the tensioner bracket to the front face of the thermostat housing. Tighten the hexagonal head bolts.
3 Hexagonal head bolt: 24 Nm {2.4 kgm}
INSTALLATION OF BELT TENSIONER

15 mm Determine the position of the belt tensioner on the bracket, then secure with the mounting bolt. Check that the tensioner positioning tab is positioned at the hole of the tensioner bracket which has no thread.
REMOVAL FROM ENGINE ASSEMBLY STAND

Engine lifting tool (Part No. 3822512) Warning:To prevent personal injury, the engine lifting equipment must be designed so that it can lift the engine safely. The dry weight of the engine plant with standard accessories installed is 612 kg. Install a suitably rated hoist and engine lifting tool (Part No. 3822512) to the engine lifting bracket, then raise the engine. Warning: When the engine is removed from the engine stand, the engine will move or fall even when slightly unbalanced. Be extremely careful to avoid personal injury. Using the hoist and lifting tool, apply lifting force to the engine. Remove the six mounting bolts holding the engine to the adapter plate. Using the hoist, lower the engine on to a suitable engine support stand or transportation skid. Remove the hoist and lifting tool from the engine.
114 SERIES
13-105
ASSEMBLY OF ENGINE
INSTALLATION OF FAN HUB ASSEMBLY

10 mm Install the fan hub. The fan hub assembly must be able to rotate freely. Tighten the mounting bolts.
INSTALLATION OF FUEL INJECTION PUMP

Use Loctite to prevent the fuel injection pump from coming off the installation tool. Coat the stud thread with Loctite 242.
13 mm Install the stud with double nut as shown in the diagram.
Engine crankshaft rotation tool (Part No. 3377371) Check that the No. 1 cylinder is at top dead center (T.D.C). 5 Rotate the crankshaft to match the direction of rotation of the engine.
13-106
114 SERIES
ASSEMBLY OF ENGINE
In the fuel injection pump, timing pin , which determines the position of the pump shaft at No.1 cylinder TDC, is inside the governor housing. After installing the pump, reverse the pin and store it in housing . 5 The timing pin on the EP-9 Nihon Denso pump is set in the body proper.
24 mm Remove the access plug.
Remove the timing pin.
If the timing teeth are not aligned with timing pin hole, rotate the shaft of the fuel injection pump and align the timing teeth.
114 SERIES
13-107
ASSEMBLY OF ENGINE
Reverse the position of the timing pin and align it with the timing pin slot at the top of the timing teeth inside the pump. Using the access plug, install the timing pin and fix it in position.
Install the fuel injection pump O-ring. Check that the position of the O-ring is correct and that it is not damaged. Add oil to the mounting flange of the fuel injection pump. 5 Before installing the gear, clean the inside diameter of the fuel injection pump drive gear and the outside diameter of the shaft, and dry them. 5 The O-ring of the oil supply orifice on the Bosch PES.P fuel injection pump is inside the gear housing. 5 The semicircular key is not necessary for the drive gear. When using a new replacement pump, remove the key and dispose of it. Position the pump flange on the mounting stud.
13-108
114 SERIES
ASSEMBLY OF ENGINE
15 mm and 13 mm, fuel injection pump mounting tool kit (Part No. 3823956) Install the mounting nut. Rear support bracket:
3 Mounting nut: 44 Nm {4.5 kgm) 3 Mounting bolt for M8 pump bracket:
3 Mounting bolt for M10 block and bracket:
24 Nm {2.4 kgm}
Top support bracket:
45 Nm {4.6 kgm} 24 Nm {2.4 kgm}
22 mm (PES6A fuel injection pump) 27 mm (PES6MW fuel injection pump) 30 mm (PES6P fuel injection pump) Caution: To prevent damage to the timing pin, do not exceed the specified tightening torque. This is the final tightening torque for the retaining nut. Install the fuel injection pump drive gear, then install the nut and washer.
3 Nut: 12 Nm {1.2 kgm}
Remove the meshing of the timing pin.
24 mm Remove the fuel injection pump timing pin plug. Reverse the position of the pin, then install the pin, plug, and seal washer.
3 Plug: 15 Nm {1.5 kgm}
114 SERIES
13-109
ASSEMBLY OF ENGINE
22 mm (PES6A fuel injection pump) 27 mm (PES6MW fuel injection pump) 30 mm (PES6P fuel injection pump) Tighten the drive gear nut of the fuel injection pump.
3 Pump drive gear nut:
PES6A: 92Nm {9.4kgm} PES6MW: 104Nm {10.6kgm} PES6P: 195Nm {19.9kgm}
Caution: Before starting to operate the engine, add oil to the governor housing. If you forget to add oil, there will be premature wear of the governor weight. 10 mm hexagonal wrench Remove the access plug. Add the following amount of clean 15W-14 engine oil. Install the access plug. RQV: 750ml RQVK: 750ml RSV: 450ml
Install the access plug.
3 Access plug: 28 Nm {2.9 kgm}
Put the dial gauge in contact with the tooth of the fuel injection pump drive gear.
Record the overall movement of the indicator as the backlash of the fuel injection pump drive gear. 5 When checking the backlash, if the neighboring gears are not prevented from moving, the reading will be the total for both gears. Limit for backlash (A & B) for oil pump and idler gear mm Min. 0.08 Max. 0.33
13-110
114 SERIES
ASSEMBLY OF ENGINE
INSTALLATION OF FUEL INJECTION PUMP, FUEL SUPPLY LINE

17 mm and 19 mm Using a new seal washer, install the fuel supply line to the fuel injection pump. Tighten the I-joint. Install the fuel return line.
INSTALLATION OF FUEL FILTER HEAD

When using the two-tandem optional filter, install the adapter and O-ring.
3 Adapter: 11 Nm {1.1 kgm}
Install the O-ring to the two-tandem filter head. Coat the O-ring and center hole with clean 15W-40 engine oil.
24 mm Install the dual filter head. Tighten the nut.
3 Nut: 32 Nm {3.2 kgm}
114 SERIES
13-111
ASSEMBLY OF ENGINE
INSTALLATION OF FUEL FILTER

Temporarily install the fuel filter. When the engine is ready to be run, fill the filter with clean No. 2 diesel fuel. When the gasket contacts the filter head, tighten a further 1/2 turns.
INSTALLATION OF FUEL INJECTION PIPE (HIGH-PRESSURE SIDE)

10 and 17 mm (PES6A and PES6MW Fuel Injection Pump) 10 and 19 mm (PES6P Fuel Injection Pump) Loosen the vibration isolator capscrews so the fuel lines can be easily moved. 5 To prevent breakage to the fuel lines, they must be connected to the injector and fuel injection pump in a "free state" without forcing the connecting nuts. Since the fuel lines are properly sized for specific application, bending should not be necessary. Caution: If removed, install the support clamp in the original position and make sure the lines do not contact each other or another component. Install the lines in the reverse order of removal. 5 efore installing the fuel injection pipe to the injector of fuel injection pump, clean the high-pressure fuel injection pipe relief and be sure that there is no accumulated dirt. Tighten the joints and mounting equipment of the high-pressure fuel injection pipe carefully.
3 Fuel injection pipe: 24 Nm {2.4 kgm} 3 Mounting bolt of support bracket:
3 Anti-vibration clamp bolt: 6 Nm {0.6 kgm}
24 Nm {2.4 kgm}
13-112
114 SERIES
ASSEMBLY OF ENGINE
INSTALLATION OF BOOST COMPENSATOR TUBE

17 mm, 13 mm Install the boost compensator tube.
3 Tube nut: 8 Nm {0.8 kgm}
INSTALLATION OF FRONT CRANKSHAFT SEAL

Maintenance tool (Part No. 3824499) Leave the plastic pilot installation tool inside the oil seal. Set the oil seal dust lip surface facing up, then position the seal with the maintenance tool (Part No. 3824499).
Support the front travel oil seal flange properly to prevent damage to the oil seal and front cover. From the rear face of the cover, set the oil seal facing to the front and insert it into the front cover. Push the oil seal until the bottom of the maintenance tool contacts the front cover.
INSTALLATION OF FRONT CRANKSHAFT WEAR SLEEVE

5 Check the wear groove of the crankshaft seal contact surface visually. If the groove is worn to a depth where your fingernails catch in it, it is necessary to install a wear sleeve to prevent leakage of oil. 5 The oil seal used with the wear sleeve has an inside diameter larger than the standard seal. It is impossible to replace and use 2 seals. For details of the correct part No, see the appropriate parts catalog for the 114 Series.
114 SERIES
13-113
ASSEMBLY OF ENGINE
Front shaft wear sleeve installation tool (Part No. 3823908) Using driver , install the wear sleeve to the correct position on the crankshaft. The kit consists of the following parts. Reference number Part name Driver Spacer M14 x 1.5 x 60 mm Cotter pin Q'ty 1 2 2 2
Coat the inside diameter of driver and the thread of the bolt thinly with 15W-40 engine oil.
Using an iron oxide cloth or equivalent part, remove the rust, corrosion, and accumulated dirt from the crankshaft flange. Coat the crankshaft flange thinly with 15W-40 engine oil. Install with the chamfered end of the wear sleeve at the end of the crankshaft.
Align the counterbore end of driver sleeve.
with the wear
13-114
114 SERIES
ASSEMBLY OF ENGINE
Pass 2 mounting bolts (without spacer or cotter pin) through the driver and install to the crankshaft. Align the wear sleeve and driver perpendicular to the crankshaft. Tighten the mounting bolts by hand.
To prevent damage to the wear sleeve, do not tighten any bolt more than 1/2 turns. Tighten the mounting bolts in turn until the sleeve is installed to a depth of approx. 16 mm.
Remove the mounting bolts and fit a spacer to each mounting bolt. Then install the mounting bolts again.
Tighten the mounting bolts in turn until the bottom of the driver contacts the end of the camshaft.
114 SERIES
13-115
ASSEMBLY OF ENGINE
Remove the driver. When keeping in storage, use the cotter pin and secure the mounting bolts and spacers to the tool.
INSTALLATION OF GEAR COVER

Caution: To prevent leakage from the crankshaft seal lip and seal surface, drain the oil completely. Clean the front seal of the cylinder block thoroughly.
To make it easier to align the position of the gasket, use 2 guide pins (M8 x 1.25 x 17 mm). Coat both sides of the gasket with Three Bond sealant. Using the seal pilot tool, install the gasket and gear cover to the nose of the cylinder block. Caution: The nose of the cylinder block and cover is different according to the seal pilot tool. Tighten the mounting bolts. 10mm Tighten the mounting bolts of the gear cover.
Remove the seal pilot tool from the nose of the crankshaft.
13-116
114 SERIES
ASSEMBLY OF ENGINE
When using, install the crankshaft oil seal dust seal as follows. 5 Push dust seal to the crankshaft to separate the part No. surface from the engine. Liquid detergent is useful when assembling.
INSTALLATION OF TACHOMETER DRIVE

Install the tachometer drive and cable.
INSTALLATION OF CRANKSHAFT PULLEY, VIBRATION DAMPER

21 mm, engine crankshaft rotation tool (Part No. 3377371) Install the crankshaft pulley/vibration damper. Tighten the mounting bolts.
Using the engine crankshaft rotation tool, make sure that the engine cannot rotate. Install the fan hub pulley, then secure with the mounting bolt. 5 If the belt has already been installed, it is easier to tighten the mounting bolts.
114 SERIES
13-117
ASSEMBLY OF ENGINE
INSTALLATION OF BELT
3/8 inch square drive Raise the tensioner and install the belt. Operating hint: If it is difficult to install the drive belt (the belt may be too short), set the belt on top of the grooved pulley and support the tensioner while sliding the belt over the water pump pulley.
13 mm Tighten the fan hub pulley mounting bolts.

INSTALLATION OF ENGINE FRONT SUPPORT

15 mm Install the engine front support. Tighten the mounting bolts.
INSTALLATION OF FUEL FEED PUMP

10 mm Coat the gasket with Three Bond sealant. Install the fuel feed pump and the new gasket. Tighten the mounting bolts.
13-118
114 SERIES
ASSEMBLY OF ENGINE
INSTALLATION OF FUEL PIPING TUBE (LOW-PRESSURE SIDE)

14mm,17mm,20mm Install the fuel piping tube to the fuel feed pump. Using two wrenches, tighten the connector to the fuel feed pump.
3 Connector: 24 Nm {2.4 kgm}
INSTALLATION OF FUEL PUMP SOLENOID

8 mm Install the solenoid, then connect the wiring.
INSTALLATION OF AIR COMPRESSOR

14mm, 15mm, 19mm Caution: Make sure the oil drain notch in the gear housing is not blocked. The gasket must be installed with the side marked "This Side Toward Gear Housing" is facing the gear housing. Use a new gasket. Install the air compressor. Tighten the two mounting nuts.
3 Nut: 77 Nm {7.9 kgm}
The air compressor can be installed to the 114 Series engine at any time. Install the mounting spacer to the engine block, use the 40 mm long capscrews and tighten finger tight.
114 SERIES
13-119
ASSEMBLY OF ENGINE
Using a bolt of a length of 30 mm, install air compressor brace to mounting spacer and adapter at the top of the air compressor. Check that the brace and spacer are aligned and the parts are not obstructed. Tighten uniformly to the proper tightening torque.
9/16 inch
3 Flange nut: 8 Nm {0.8 kgm}
Install the oil supply line.
15/16 inch Caution: When using rubber grommets for the cooling system, to prevent leakage of the coolant, be careful not to crack or cut the grommets when installing. Install the cooling system.
3 Flange nut: 35 Nm {3.6 kgm}
Install the inlet and outlet joints, and tighten.

3 Inlet port flange nut: 65 Nm {6.6 kgm}
Mounting bolt:
3 Outlet port flange nut: 24 Nm {2.4 kgm}
(compressor cylinder head joint: 1/2 NPT)
13-120
114 SERIES
ASSEMBLY OF ENGINE
INSTALLATION OF ENGINE ACCESSORY

Depending on the need, install the cover plate or additional gear drive accessory (hydraulic pump, compressor for air conditioner, etc.).
114 SERIES
13-121
REPAIR AND REPLACEMENT OF PARTS
15 REPAIR AND REPLACEMENT OF PARTS

OUTLINE ..................................................................... 15- 2 REPAIR GUIDE LINE .......................................... 15- 2 WHEN SHOULD SUBSTITUTE REPAIRS BE CARRIED OUT ............................................................. 15- 2 INSPECTION ....................................................... 15- 2 TO ENSURE SAFETY, FOLLOW ALL INSTRUCTIONS IN MANUAL.............. 15- 2 FOLLOW WASHING METHODS GIVEN IN MANUAL...................................................... 15- 2 FOLLOW INSPECTION METHODS GIVEN IN MANUAL...................................................... 15- 2 REPAIR METHODS FOR SCREWS USING COIL THREAD INSERT .......................... 15- 3 METHOD FOR USING TAPER THREAD PLUGS TO SEAL POCKETS AND SMALL HOLES IN CASTINGS........................................................... 15- 4 REPAIR PROCEDURE ........................................ 15- 4 METHOD FOR REPAIRING TAPER THREAD PLUG HOLES WORN BY LARGE SIZE COPPER PLATED PLUGS ............ 15- 7 METHOD OF USING FILLER METAL IN EMERGENCY REPAIRS.............................................................. 15- 8 INSPECTION FOR REUSE OF CYLINDER BLOCK... 15- 9 INSTALLATION OF EXPANSION PLUGS .................. 15- 13 INSTALLATION OF PIPE PLUGS ....................... 15- 13 INSTALLATION OF EXPANSION PLUG TO CAMSHAFT HOLE............................................... 15- 16 REMOVAL OF CAMSHAFT BUSHING ....................... 15- 17 CLEANING OF CAMSHAFT BUSHING HOLE .... 15- 17 INSTALLATION OF CAMSHAFT BUSHING ............... 15- 18 CLEANING AND INSPECTION OF CYLINDER LINERS BEFORE REUSING THEM.................................. 15- 19 CLEANING OF CYLINDER LINERS ................... 15- 19 INSPECTION OF CYLINDER LINERS ................ 15- 20 CLEANING AND INSPECTION OF PISTON BEFORE REUSING IT......................................... 15- 22 REMOVE THE PISTON RINGS........................... 15- 22 CLEANING OF PISTONS .................................... 15- 22 INSPECTION OF PISTONS ................................ 15- 23 CLEANING AND INSPECTION OF CRANKSHAFT BEFORE REUSING IT......................................... 15- 25 CLEANING OF CRANKSHAFT ........................... 15- 25 INSPECTION OF CRANKSHAFT........................ 15- 25 REPLACEMENT OF CRANKSHAFT GEAR ............... 15- 29 REMOVAL OF CRANKSHAFT GEAR ................. 15- 29 INSPECTION OF CRANKSHAFT........................ 15- 29 INSTALLATION OF CRANKSHAFT GEAR ......... 15- 30 CLEANING AND INSPECTION OF MAIN BEARINGS BEFORE REUSING THEM.................................. 15- 32 GENERAL INFORMATION.................................. 15- 32 CLEANING OF MAIN BEARINGS ....................... 15- 32 INSPECTION OF MAIN BEARINGS.................... 15- 32 INSPECTION OF THRUST BEARING ................ 15- 33 CLEANING AND INSPECTION OF MAIN BEARING CAPS AND MOUNTING BOLTS BEFORE REUSING THEM 15CLEANING .......................................................... 15INSPECTION....................................................... 15CLEANING AND INSPECTION OF CONNECTING ROD BEARINGS BEFORE REUSING THEM ................................. 15CLEANING OF CONNECTING ROD BEARINGS 15INSPECTION OF CONNECTING ROD BEARINGS ............... 15CLEANING AND INSPECTION OF CONNECTING RODS BEFORE REUSING THEM ................................. 15CLEANING OF CONNECTING RODS................ 15INSPECTION OF CONNECTIONG RODS ......... 15INSPECTION OF CONNECTING RODS FOR BEND AND TORSION.................................................... 15CALIBRATION OF FIXING TOOL ....................... 15INSPECTION OF ALIGNMENT OF CONNECTING RODS................................. 15REPAIR PROCEDURE FOR CONNECTING RODS................................. 15REPLACEMENT OF CONNECTING ROD BUSHINGS 15REMOVAL ........................................................... 15INSTALLATION ................................................... 15INSPECTION....................................................... 15REPLACEMENT OF VALVE INSERTS OF CYLINDER HEAD................................................ 15REMOVAL ........................................................... 15INSPECTION....................................................... 15ASSEMBLY ......................................................... 15INSPECTION OF VALVE GUIDES ..................... 15INSPECTION OF VALVE SEAT INSERTS ......... 15INSPECTION OF VALVE SPRINGS ................... 15INSPECTION OF VALVE STEM SEAL ............... 15INSPECTION OF VALVES.................................. 15GRINDING OF VALVES...................................... 15GRINDING OF VALVE SEAT INSERTS ............. 15ASSEMBLY ......................................................... 15INSTALLATION OF PIPE PLUGS....................... 15REPLACEMENT OF VALVE GUIDES OF CYLINDER HEAD................................................ 15DISASSEMBLY ................................................... 15INSPECTION....................................................... 15ASSEMBLY ......................................................... 15CYLINDER HEAD-PRESSURE TEST ........................ 15VACUUM TEST ON VALVE SEATS OF CYLINDER HEAD................................................ 15CLEANING AND INSPECTION OF CYLINDER HEAD BOLTS ................................................................. 15CLEANING .......................................................... 15INSPECTION....................................................... 15FREE LENGTH - MEASUREMENT .................... 1534 34 34
35 35 35 37 37 37 40 40 41 41 42 42 44 46 47 47 49 49 50 51 52 53 53 54 55 59 59 62 62 62 62 65 67 69 69 69 70
114 SERIES
15-1
OUTLINE
OUTLINE
REPAIR GUIDE LINE
Since the latest diesel technologies are applied to the 114 Series engines, it is required to perform the conventional repair works at a high quality level for those engines. As a part of support to the maintenance of the 114 Series engines, new spare parts are available in every part of the world.
FOLLOW WASHING METHODS GIVEN IN MANUAL

When repairs have been completed, check that all mental particles produced by the machining have been completely removed and that the applicable parts have been completely cleaned.
WHEN SHOULD SUBSTITUTE REPAIRS BE CARRIED OUT

In the following explanation of the procedures, mention is also made of a separate repair method to use instead of large-scale replacement of engine parts. The decision is governed by various conditions, such as technical demands, possibility of use, cost, and consideratoins related to the length of the downtime of the equipment.
FOLLOW INSPECTION METHODS GIVEN IN MANUAL

After completing repairs, carry out the necessary inspections to check that the applicable parts fulfill the technological requirements needed to withstand future continued use as an engine component.
INSPECTION
This procedure manual assumed that the component parts have already been checked, and that the points which do not match the standard have been checked during repair or overhaul. This manual covers only inspection requirements related directly to the alternative repair procedures.
TO ENSURE SAFETY, FOLLOW ALL INSTRUCTIONS IN MANUAL

For cleaning solvents and other substances used during repair of the engine, always keep to the recommendations of the manufacturer. With regard to tools and maintenance facilities, always observe practices that ensure compete safety.
15-2
114 SERIES
REPAIR METHODS FOR SCREWS USING COIL THREAD INSERT
REPAIR METHODS FOR SCREWS USING COIL THREAD INSERT

The 114 engine uses metric cap screws. M8 x 12.5 25 Length in mm Distance between threads in mm Main thread diameter in mm The coil insert is a precision made thread repair liner made of stainless steel wire in a coil shape. These coils are designed so that the diameter becomes larger the stepped hole when they are not machined. After an insert is installed, it expands to the outer wall of the stepped hole. When the insert expands in this way it becomes fixed in position. The standard insert is made of stainless steel wire, but other materials can also be used in order to fulfill special requirements. Only four steps are needed to repair the thread by this method: making holes, steps, peeling off tang, and removal. In parts using thin wall surface material, the insert can be used to restore any damaged or broken thread to its original size. One more advantage of these inserts is that they do not wear even with repeated use.
114 SERIES
15-3
METHOD FOR USING TAPER THREAD PLUGS TO SEAL POCKETS AND SMALL HOLES IN CASTINGS
This explanation of the repair procedure is a guideline for the method of use of a taper thread plug to repair slight defects which cause leakage in castings, such as pin holes, blow holes, and pocket of dirt or slag or sand. These defects can be repaired in the following cases. 1. Oil or water continues to leak out from the engine. 2. The locations of the defect is at a place where there is no strain on the casting, or in portions where no other machining has been carried out. A taper thread plug is also used for repairing cracks, but the guideline for repairs of castings with cracks is not included here. This method cannot be used for carrying out repairs in the following places. 1. Oil passage boss. 2. Cast portions in positions where a drilled hole or mounted taper thread plug would interfere with the operation of the engine or any of the engine components. 3. The wall portion of the casting between the water passage and oil passage. 4. The boss of the cylinder head cap screw. A taper thread plug can be used for repairing castings in the following cases. 1. Defects which can be removed with a tap drill. 2. Places where the necessary plug size is a maximum of 27.53 mm (1.084 in). 3. Places with defects where the maximum thickness of the wall is at least 3.97 mm (5/32 in).
REPAIR PROCEDURE
There is a special tap drill size and tap size for each size of taper thread plug. Check that you are using the correct size of tap drill and tap to match the size of the taper thread plug.
15-4
114 SERIES
Ironite Part No. 210200 210235 210237 210420 210421 210490 210491 210590 260780 261080
X Diameter at small end mm 5.08 5.97 8.32 10.67 10.67 12.45 12.45 14.99 19.81 27.53
Y Thread length mm 3.8 23.8 36.5 25.4 36.5 25.4 36.5 25.4 25.4 25.4
Drill size 11/64 13/64 5/16 25/64 25/64 15/32 15/32 23/32 23/32 1.00
Ironite tap No. 530200 530235 530237 530420 530420 530490 530590 530780 530780 531080
Cummins tap Part No. 555228 555229 555230 555231 555232 555234 555234 555236 555236 555237
A: Standard pipe plug B: Taper threaded plug
1. Using a portable disc grinder or wire brush, removed all paint and rust from the defective area. Caution: If repair is carried out with the engine still installed to the machine, be careful not to let any chips or particles enter the engine. 2. Make a hole with the correct size of tap drill to match the plug that is used. Make sure that the size of the drill bit is large enough to completely remove the problem area. Do not use a drill bit that is larger than necessary. After making the hole, remove all the chips and particles. 3. Check the hole made by the drill. If there is any problem with the wall of the hole, make a hole for the next largest plug. Repeat this procedure until there is a hole with no defects in the wall. Do not forget that the maximum diameter of the hole is 25.4 mm
The thickness of the wall of the casting at the problem point must be at least 3.97 mm 4. Use the correct size of taper to cut the thread in the hole. A minimum of at least four complete threads is necessary to seal the plug. Be sure to remove all chips and particles after grinding. 5. Coat the plug thread with Loctite 601 ST1272-12 Loctite compound or the equivalent. 6. Insert the plug and tighten it. 7. Using a metal saw, cut off the plug. Leave at least 0.794 mm of the plug from the surface.
114 SERIES
15-5
8. Using a small ball peen hammer flatten the protruding portion of the plug. Flatten the plug so that the top thread of the plug seals the top thread of the hole. 9. Leave for at least 30 minutes for the Loctite sealant to harden. 10. Using a hand grinder or file, make the top of the plug level with the surface of the casting. Caution: If repairs have been carried out to the water passage or oil passage wall surface, the plug must be tested with an air pressure of 343 kPa {3.5 kg/cm2}. Apply pressure to the passage and coat the top of the plug with soapy water to check that no bubbles are formed. If bubbles are formed, it means that the leakage has not been properly repaired. Start again from Step 2 of the above procedure and install the next size of taper thread plug. 11. If necessary, paint the repaired portion with paint of a matching color.
15-6
114 SERIES
METHOD FOR REPAIRING TAPER THREAD PLUG HOLES WORN BY LARGE SIZE COPPER PLATED PLUGS
METHOD FOR REPAIRING TAPER THREAD PLUG HOLES WORN BY LARGE SIZE COPPER PLATED PLUGS
It is possible to repair a worn taper thread plug hole using the following method. Clean the thread portion with trichloroethylene III or the equivalent. Fit the correct size of pipe tap to the thread. Install a copper plated (large size) taper thread plug using taper thread plug sealant.
114 SERIES
15-7
METHOD OF USING FILLER METAL IN EMERGENCY REPAIRS
METHOD OF USING FILLER METAL IN EMERGENCY REPAIRS

The explanation for this procedure gives information regarding the method of use of compound filler metal in emergency repairs. Repair methods using filler metal must not be used as a substitute for permanent repair or replacement of parts. Filler metal can be used to provide temporary limitation of permeation, adjustment of the surface, or cover for chipped parts. Do not attempt to use this method for repair of components or parts related to safety. It is possible to obtain metal filler based on various metals, such as iron, brass, or aluminium. Check that the filler metal matches the material of the part being repaired. The filler metal must have the same resistance to temperature, stress, and pressure as the material of the part being repaired. Metal filler compounds have many purposes: some can be used to join different types of metals, while others cannot be used for such purposes. To achieve a good result, follow the recommendations of the manufacturer.
15-8
114 SERIES
INSPECTION FOR REUSE OF CYLINDER BLOCK

5 Set the cylinder block on a level place to measure its dimensions. If it is set on an engine stand, it is twisted and its dimensions may not be measured accurately. Inspect the all gasket fitting surfaces. Visually inspect for burrs and damages. Remove burrs with a medium grindstone or iron oxide and cloth.
Straight Edge and Feeler Gauge Visually inspect the top surface for damage. Check the top surface for flatness between each cylinder. Cylinder Block Flatness Specification mm End-to-End 0.075 Side-to-Side 0.075 Caution: Do not proceed with the repair if the cylinder block head deck is damaged or not flat. The engine will have to be removed for resurfacing the block. 5 The cylinder block head deck can be resurfaced in a machine shop and a thicker surface head gasket installed to keep the piston-to-head clearance the same.
If the cylinder block surface is cut by 0.25 mm, stamp an X at the upper right corner of the rear face of the block. If the cylinder block surface is cut by 0.50 mm, stamp one more X next to the first X.
114 SERIES
15-9
Consult the 114 Series parts catalog for the correct head gasket to be used with resurfaced blocks to be sure of proper piston to value clearance. 5 The gaskets are notched to aid in identification. The standard gasket does not have a notch. A : Use where block deck has been resurfaced 0.25 mm (two notches) B : Use where block deck has been resurfaced 0.50 mm (three notches) Measure the cylinder liner bore in the block. Cylinder liner bore in block (Press Fit Bore) mm Min. 130.900 Max. 130.990 Crack detecting kit (Part No. 3375432)
Caution: Clean all deposits and debris from searing surfaces A, B and C. Use Scotch-Brite7448 or equivalent and cleaning solvent to polish the surfaces. Due to the critical machined tolerances, care should be taken not to remove any additional material. Use the crack detecting kit (Part No. 3375432) or equivalent. Inspect the counterbore leg for a crack. If surface C has cracks or signs of extreme wear, the counterbore will require machining and the installation of shims for the correct liner protrusion. Cylinder liner shims are available as follows: Cylinder liner shim thickness Part No. mm 3924445 0.25 3924446 0.38 3924447 0.51 3924448 0.76 3924449 1.00
15-10
114 SERIES
Measure the depth of the liner counterbore. Boring depth of cylinder from top of cylinder block head mm Min. 122.930 Max. 123.000
Distance from top of cylinder block head to top of main bearing hole mm Min. 309.4 Max. 309.6
Distance from top of cylinder block head to center line of main bearing hole mm Min. 361.90 Max. 362.10
Check the main bearing holes for wear and damage. Install new main bearings and tighten the main caps, then measure the diameters of the holes.
3Main cap bolt: 176 Nm {17.9 kgm}
Diameter of main bearing hole With new bearings installed: Without bearings 5 Min. Max. Min. Max. mm 98.079 98.125 104.982 105.018
The radial runout must not exceed 0.0127 mm.
114 SERIES
15-11
Check the camshaft holes for a scratch and excessive wear. Measure the camshaft holes with a bore gauge. Measure each camshaft hole at 2 places. Measure at any place first, then measure at a place turned by 90 from the first measuring point. Diameter of camshaft hole (Max.) mm Without bushing 64.01 With bushing fitted 60.12
Check the tappet holes for a scratch and excessive wear. Diameter of tappet hole mm Min. 16.000 Max. 16.055
15-12
114 SERIES
INSTALLATION OF EXPANSION PLUGS

Caution: Do not install any expansion plug or pipe plug in the block before inspection and all process which needs any tool are finished. This must be observed to prevent dirt from staying in the oil path. Caution: Excessive sealant may flow in the engine and can damage the other parts. Before starting the engine, dry the sealant for at least 2 hours. If the sealant is not dried, the expansion plug may come out of the hole. Apply 2 mm beads of expansion plug lock N seal, part No. 3375068, or equivalent to the outside of each expansion plug and inside of each expansion plug hole. 5 Install each expansion plug to the correct depth with an expansion plug driver. Use the following expansion plug drives. Part No. of tool 3822372 3823521 3376816 3823522 3823523 3823524 Part No. of expansion plug 3900955 3902606 3900957 156075 3905401 3900965 Dimension of expansion plug (in.) 0.375 0.8125 1.00 1.1875 1.375 2.250
Caution: Do not install the expansion plugs too deep. If they are installed too deep, they may block the holes which are crossing them. If a plug is not installed straight and flat, replace it with new one. Install each expansion plug so that its rim will be 0.5 mm 1.0 mm deeper than the hole edge.
INSTALLATION OF PIPE PLUGS

Apply beads of pipe plug sealant (part No. 3375066) or equivalent to the threads. Tighten the pipe plugs to the torque shown in the following table.
114 SERIES
15-13
Tighten each pipe plug to proper torque.

Torque for pipe plug Size Torque Outside Aluminum parts diameter of plug Nm {kgm} mm 5 {0.5} 8.1 15 {1.5} 10.4 20 {2.0} 13.7 25 {2.5} 17.3 35 {3.7} 21.6 45 {4.6} 26.7 60 {6.1} 33.5 75 {7.6} 42.2 85 {8.7} 48.3 Torque Cast steel or cast iron parts Nm {kgm} {1.5} 15 {2.0} 20 {2.5} 25 {3.7} 35 {5.6} 55 {7.6} 75 {9.7} 95 115 {11.7} 135 {13.8}
Thread in 1/16 1/8 1/4 3/8 1/2 3/4 1 11/4 11/2
Pipe plugs and expansion plugs at front cylinder block (1.) 1 inch pipe plug (2.) 13/16 inch expansion plug (3.) 1-3/8 inch expansion plug (4.) 1-1/8 inch expansion plug (5.) 1/2 inch pipe plug
Pipe plugs and expansion plugs on right side of cylinder block (1.) 2.287 inch inch expansion plug (2.) 1-3/8 inch expansion plug (3.) 1/2 inch pipe plug (4.) 13/16 inch expansion plug (5.) 3/4 inch pipe plug (6.) 1/4 inch drain valve (7.) 3/8 inch expansion plug or level gauge tube (8.) 7/8 inch expansion plug or turbocharger drain tube
Pipe plugs and expansion plugs at rear of cylinder block (1.) 1-3/16 inch expansion plug or aftercooler joint (2.) 13/16 inch expansion plug (3.) Expansion plug of camshaft hole
15-14
114 SERIES
Pipe plugs and expansion plugs on left side of cylinder block (1.) 1-3/8 inch expansion plug on oil filler side (2.) 3/4 inch pipe plug (3.) 1/8 inch pipe plug (4.) 3/8 inch expansion plug or level gauge tube
114 SERIES
15-15
INSTALLATION OF EXPANSION PLUG TO CAMSHAFT HOLE
INSTALLATION OF EXPANSION PLUG TO CAMSHAFT HOLE

Apply a bead of LOCTITE 277 to the outside of the camshaft expansion plug.
Position the expansion plug with the projection side out.
Expand the plug with a large brass drift and a hammer.
Expand the expansion plug until its projected part is lower than the cylinder block surface.
15-16
114 SERIES
REMOVAL OF CAMSHAFT BUSHING
REMOVAL OF CAMSHAFT BUSHING

Tool (3823509) to remove and fit camshaft bushing Drive the bushing out of the cylinder block hole.
CLEANING OF CAMSHAFT BUSHING HOLE

Remove burrs and sharp edges from the hole with a fine emery cloth and solvent.
114 SERIES
15-17
INSTALLATION OF CAMSHAFT BUSHING
INSTALLATION OF CAMSHAFT BUSHING

Match the oil holes of the camshaft bushing and cylinder block to each other. 5 Set the oil hole of the camshaft bushing at the 7o'clock position when seen from the front side of the engine.
All-round bushing installer 5 Install the front camshaft bushing to a depth of 4.5 mm below the front cylinder block. Install all of the other bushings flush with the webs of the cam shaft holes.
Check that the oil holes are matched to each other. A rod 3.2 mm in diameter must go through the oil hole of the camshaft bushing freely.
Measure the inside diameter of the installed camshaft bushing. Inside diameter of camshaft bushing (after installed) mm Min. 60.058 Max. 60.112
15-18
114 SERIES
CLEANING AND INSPECTION OF CYLINDER LINERS BEFORE REUSING THEM

CLEANING OF CYLINDER LINERS
Caution: Do not use any abrasives in the ring travel area of the liner. The liner can be damaged. Use a soft wire brush or a fine fibrous abrasive pad such as Scotch-Brite7448 or equivalent (Part No. 3823258) to clean the flange seating area.
Warning: When using a stream cleaner, wear protective clothing and safety glasses or a face shield. Hot steam can cause serious personal injury. Use solvent or steam clean the liners and dry with compressed air.
Use clean 15W-40 oil to lubricate the inside diameter of the liners. Allow the oil soak in the liner for 5 to 10 minutes.
Use lint-free paper towels to wipe the oil form the inside of the liners. Continue to lubricate the inside of the liners and wipe clean until the paper towel shows no gray or back residue.
114 SERIES
15-19
INSPECTION OF CYLINDER LINERS

Visually inspect the liners for cracks on the inside and outside diameters.
Inspect for cracks under the flange.
Visually inspect outside diameter and seat area for excessive corrosion or pitting. 5 Pits must not be more than 1.6 mm [0.06inch] deep. Replace the liner if the pits are too deep or if the corrosion cannot be removed with fine emery cloth.
Inspect the inside diameters for vertical scratches deep enough to be felt with a fingernail. 5 If the fingernail catches in the scratch, the liner must be replaced. Visually inspect the inside diameter for scuffing or scoring.
15-20
114 SERIES
Visually inspect the inside diameter for liner bore polishing. A moderate polish (A) produces a bright mirror finish in the worn area with traces of the original hone marks or an indication of an etch pattern. A heavy polish (B) produces a bright mirror finish in the worn area with no traces of hone marks or an etch pattern.
Replace the liner if: A heavy polish is present over 20 percent of the piston ring travel area. Both moderate and heavy polish over 30 percent of the piston ring travel area and one half (15 percent) is heavy polish.
Part No.3375072, Dial Bore Gauge Measure the liner inside diameter in four places 90 apart at the top and bottom of the piston travel area. Cylinder liner I.D. Min. Max. mm 114.000 114.040
Measure the outside diameter of the liner top press fit area. Cylinder liner O.D. (Top press fit) mm Min. 130.938 Max. 130.958
114 SERIES
15-21
CLEANING AND INSPECTION OF PISTON BEFORE REUSING IT

REMOVE THE PISTON RINGS
Piston ring expander (Part No. 3823137) Remove the piston rings. Place a tag on the rings and record the cylinder number of the piston on the tag.
CLEANING OF PISTONS
Caution: Be sure the cleaning solvent is approved for aluminum. Damage to the piston can result. Allow the piston to soak for a minimum of 30 minutes in a tank containing an approved cleaning solvent for aluminum. 5 For the best cleaning result, leave the pistons in the cleaning solvent for several hours or all night
Use a hot, soapy solution and a non-metallic brush to remove carbon deposits. Caution: Do not use a metal brush. A metal brush will damage the piston ring grooves. Do not use glass beads, walnut shell or plastic bead blasting to clean the piston ring grooves or pin bores. This can cause the pin bore to crack or the rings to not seat.
Warning:When using a stream cleaner, wear protective clothing and safety glasses or a face shield. Hot steam can cause serious personal injury. Use steam to clean the pistons. Dry with compressed air.
15-22
114 SERIES
INSPECTION OF PISTONS
Inspect the piston for damage and excessive wear. Check the top ring grooves, skirt and pin bore. 5 Dimensional inspection of the piston is required only when the cause of the lack of sealing is not apparent.
Check the piston for a wavy edge at a flange between the grooves where the ring is bruised. This defect may be the cause of lowering of the sealing effect.
Visually inspect the piston bowl skirt for cracks or damage. 5
, pin bore
and
Do not use pistons with cracks.
Measure the piston pin hole when the piston temperature is 20C. Piston pin hole I.D. Min. Max. 5 mm 45.006 45.025
Add 0.013 mm to the inside diameter of the hole for a temperature rise of 5C up to 32C.
114 SERIES
15-23
Visually inspect the piston pin for scratches, grooves, or other damage. Measure the piston pin outside diameter. Piston pin O.D. Min. Max. mm 44.993 45.003
Measure the piston skirt diameter as illustrated. Piston skirt O.D. Min. Max. mm 113.814 113.886
Use a micrometer and Part No. 3823966, piston ring groove gauge, to measure the wear of the top ring groove keystone angle. Use Part No. 3823965, piston ring groove gauge, to measure the wear of the second ring groove keystone angle. Piston ring groove (Keystone angle) Ring mm Top: Min. 113.938 Second: Min. 114.323
Use a new piston ring and feeler gauge to measure the side clearance of the rectangular second and oil control ring grooves. Piston ring clearance (Rectangular groove) Ring mm Second: Min. 0.070 Max. 0.150 Ring: Min. 0.020 Max. 0.130
15-24
114 SERIES
CLEANING AND INSPECTION OF CRANKSHAFT BEFORE REUSING IT

CLEANING OF CRANKSHAFT
Polish the machined surfaces with fine iron oxide and cloth. Clean the oil holes with a hard brush.
Warning: When using a steam cleaning machine, put on the protective clothes and safety goggles or a protective mask. Hot steam can injure a man seriously. Clean the crankshaft with steam, then dry it with compressed air. Check that the dirt was blown out of the screw holes and oil holes at each end of the crankshaft.
INSPECTION OF CRANKSHAFT
Visually inspect the bolt hole threads for damage. Repair the bolt holes by the following method. 5 Cut threads. Metric thread inserting kit (Part No. 3822709) If 2 or more bolt holes are damaged at 1 end of the crankshaft, replace the crankshaft.
Measure the oil seal contact area at the front and rear wear grooves of the crankshaft. Wear groove made by front and rear oil seals of crankshaft mm Max. 0.25 The front and rear wear sleeves are available when the crankshaft is worn more than the limit.
114 SERIES
15-25
Check the connecting rod and main journal of the crankshaft for a deep flaw, burn, etc.
Measure the journal diameter of the connecting rod with a micrometer. Journal diameter of connecting rod (Min.) mm Standard 75.962 0.25mm Machined 75.712 0.50mm Machined 75.462 0.75mm Machined 75.212 1.00mm Machined 74.962 Clearance of bearing: Subtract the crankshaft journal diameter from the inside diameter of the connecting rod after the bearing is fitted. Max. clearance of bearing: 0.117 mm
Bearing journal of connecting rod mm Circularity Max. 0.050 Taper Max. 0.013
Diameter of main journal (Min.) mm Standard 97.962 0.25mm Machined 97.712 0.50mm Machined 97.462 Clearance of bearing: Subtract the crankshaft journal diameter from the inside diameter of the connecting rod after the bearing is fitted. Max. clearance of bearing: 0.134 mm
15-26
114 SERIES
Main journal of crankshaft Circularity Taper Max. Max. mm 0.050 0.013
The following oversized main bearing and thrust bearing can be used for a crankshaft machined to an under-size. Oversize 0.000 0.25mm 0.50mm 0.75mm 1.00mm Size of thrust bearing 0.000 0.25mm 0.50mm x x x x x x x x x
Journal Outside diameter
Measure the distance between the thrust faces. Distance between thrust faces of crankshaft (Standard) mm Min. 42.975 Max. 43.076
Measure the outside diameter of the rear oil seal flange. Outside diameter of rear oil seal flange of crankshaft mm Min. 129.975 Max. 130.025
114 SERIES
15-27
Measure the outside diameter of the damper pilot. Outside diameter of damper pilot of camshaft mm Min. 23.924 Max. 24.000
Coat the crankshaft with light oil to prevent rusting. If the crankshaft is not used right now, cover the oiled parts with plastic sheets to prevent dust from sticking to those parts.
15-28
114 SERIES
REPLACEMENT OF CRANKSHAFT GEAR

REMOVAL OF CRANKSHAFT GEAR
Remove the gear by using a heavy-duty bearing remover or a gear puller shown in the figure. 5 Remove the gear by using a heavy-duty bearing remover or a gear puller shown in the figure.
Remove the gear by using a heavy-duty bearing remover or a gear puller shown in the figure. Hit the splitting tool with a steel hammer weighing 0.9 1.4 kg. Repeat this method, if necessary. Remove the centering dowel pin of the gear with a dowel pin pulling tool.
INSPECTION OF CRANKSHAFT
Visually inspect the gear teeth for cracking and breakage. If any tooth is damaged, replace the gear.
Check the gear and its key way for breakage and burrs. Remove broken parts and burrs with fine iron oxide and cloth.
114 SERIES
15-29
Visually inspect the crankshaft gear journal and the hole of the gear positioning dowel pin for burrs and damage. Remove burrs with fine iron oxide and cloth.
Measure the crankshaft gear bore inside diameter. Crankshaft gear bore I.D. mm Min. 75.898 Max. 75.923
Measure the outside diameter of the crankshaft journal. Outside diameter of crankshaft journal mm Min. 75.987 Max. 76.006
INSTALLATION OF CRANKSHAFT GEAR

Drive the gear positioning dowel pin in the crankshaft with a soft hammer. The pin must be projected by 1.02 mm from the crankshaft surface.
15-30
114 SERIES
Caution: Do not exceed the specified time or temperature when heating the crankshaft gear. The gear and teeth can be damaged. Heat the Gear in an oven for a minimum of 45 minutes but not more than 6 hours. Temperature of steel gear: 177C
Lubricate the outside of the crankshaft gear journal with Lubriplate No.105 or equivalent.
Caution: Use insulated gloves, Part No. 3823730, when handling heated parts. Hot parts can cause serious personal injury. Caution: The timing mark and part number on the gear must be facing away from the crankshaft after the gear is installed. Engine damage can result if the gear is installed backwards. Remove the gear from the oven. Align the keyway of the gear with the key in the crankshaft and install the gear within 30 seconds. Caution: Do not use water or oil to cool the gear quickly. If the gear is cooled so, it may be cracked. Cool the gear in air. 5 If the gear is cooled and stopped halfway on the crankshaft, fit it completely with a drive tool.
114 SERIES
15-31
CLEANING AND INSPECTION OF MAIN BEARINGS BEFORE REUSING THEM

GENERAL INFORMATION
The engine has seven main bearings. The lower bearing shells are all the same. All of the upper bearing shells are the same except for the No.4 journal. The No.4 journal uses a flanged upper bearing shell. The flanges on the bearing control the end thrust of the crankshaft. Flanges of the bearings which use rings control the end thrust of the crankshaft.
CLEANING OF MAIN BEARINGS

Check that each bearing has a position mark. If a bearing is reused, it must be installed to its original position. Caution: Do not use a scraper or a wire brush. They can damage the bearings. Use solvent and a hard brush. Dry with compressed air.
INSPECTION OF MAIN BEARINGS

Visually inspect the main bearings for breakage, scratches, and damages. Replace the bearings which have any of the following defects. Pitting Flaking Corrosion Damage of fixed projection Scratch (having depth felt with finger nail)
Measure the thickness of the worn part of each main bearing with an outside micrometer having an end ball. Standard thickness of main bearing (used) mm Min. 3.340 Max. 3.454 If the thickness of a main bearing is less than the minimum value, discard it.
15-32
114 SERIES
The upper bearings contain two oil holes. The lower bearings do not. Both bearings are marked on the back to indicate either standard (STD) or oversize (OS).
The following oversize service main and thrust bearing combinations are available for crankshafts that have been machined undersize, either on the main journal or thrust bearing face: Oversize 0.000 0.25mm 0.50mm 0.75mm 1.00mm Size of thrust bearing 0.000 0.25mm 0.50mm x x x x x x x x x
Journal Outside diameter
INSPECTION OF THRUST BEARING

Visually inspect the faces of the thrust bearing in contact with the front side, rear side, and crankshaft for wear, cracking, and damage.
Measure the thickness of the flange of each thrust bearing. Measure the contact areas on front and rear sides. Thickness of flange of thrust bearing mm Min. 3.517 Max. 3.567 Thrust bearings 0.25 mm and 0.50 mm thicker than the standard are available. See the above table.
114 SERIES
15-33
CLEANING AND INSPECTION OF MAIN BEARING CAPS AND MOUNTING BOLTS BEFORE REUSING THEM
CLEANING AND INSPECTION OF MAIN BEARING CAPS AND MOUNTING BOLTS BEFORE REUSING THEM
CLEANING
Use solvent and a soft bristle brush to clean the cap, capscrews and bearings and dry with compressed air.
INSPECTION
Visually inspect the main caps and bolts for damage.
15-34
114 SERIES
CLEANING AND INSPECTION OF CONNECTING ROD BEARINGS BEFORE REUSING THEM

5 Make position marks on the removed bearings. When reusing any bearing, install it to its original position.
CLEANING OF CONNECTING ROD BEARINGS

Caution: Do not use a scraper or a wire brush. They can damage the bearings. Use solvent and a hard brush. Dry with compressed air.
INSPECTION OF CONNECTING ROD BEARINGS

Visually inspect the bearings Replace the bearings which have any of the following defects. 5 Pitting Little flaking Corrosion Damage of fixed projection Scratch (having depth felt with finger nail) Normal bearing wear produces a smooth finish which will wear into the lining. An exposed lining does not always indicate worn bearings. If large areas of the lining are visible in the bearings before the engine has accumulated 3,750 hours, inspect the engine for contamination from fine dirt particles and correct the problem.
Visually inspect the bearing fitting faces for breakage and burrs. If the burrs of a bearing cannot be removed with fine iron oxide and cloth, replace the bearing.
114 SERIES
15-35
Measure the rod bearing shell thickness with an outside micrometer that has a ball tip. Standard connecting rod bearing thickness mm Min. 2.43 Max. 2.471 Discard a bearing shell if its thickness is below the minimum specification.
Connecting rod bearings are identified with a part number and size stamped on the back size. Determine the size of the removed rod bearing and obtain a set of the same size. Oversize service rod bearings are available for use with crankshafts that have been machined undersize. Refer to the appropriate parts catalog.
15-36
114 SERIES
CLEANING AND INSPECTION OF CONNECTING RODS BEFORE REUSING THEM

CLEANING OF CONNECTING RODS
5 Each set of a connecting rod cap and a connecting rod must have the same letter or figure. Do not combine a new cap with a used connecting rod or combine a used cap with a new connecting rod. Remove the nuts and cap from the connecting rod. Warning: when using a steam cleaner, wear protective clothing and safety glasses or a face shield. Hot steam can cause serious personal injury. Use steam or solvent to clean the connecting rods. Clean the oil holes with a hard brush. Dry the oil holes with compressed air.
INSPECTION OF CONNECTIONG RODS

Inspect the connecting rods and caps for damage. Replace the connecting rod if the I-beam is nicked or damaged. If either of a connecting rod and its cap is fretted, replace them. If the I-beam of the connecting rod is nicked or damaged, replace it.
Visually inspect the connecting rod pin bore bushing for damage or misalignment of the oil passage and bushing.
114 SERIES
15-37
Measure the connecting rod piston pin bushing inside diameter. Connecting rod pin bore specifications (When bushing is fitted) mm Min. 45.023 Max. 45.060 5 The replacement rod bushings for service are available. For their part Nos., see the proper parts catalogues. Each bushing must be finished with a precision machine after it is installed. If a proper machine is not available, replace the bushing. See Replacement of connecting rod bushings.
Tap the connecting rod bolts in until the head is aligned and seated on the flat machined surface of the connecting rod.
Install the bearing shells in the connecting rod and cap. Install the connecting rod caps and the connecting rod nuts. 5 The connecting rod cap number must match the number on the connecting rod and be installed with the numbers aligned. Tighten the connecting rod nuts in alternating sequence.
3 Connecting rod nut:
Step 1 - 40Nm{4.1kgm} Step 2 - 80Nm{8.2kgm} Step 3 - 120Nm{12.2kgm}
Measure the connecting rod crankshaft bore inside diameter with the bearing installed. Connecting rod crankshaft bore I.D. (with bearing) mm Min. 76.046 Max. 76.104 Inside diameter of connecting rod (Without bearing) mm Min. 80.987 Max. 81.013
15-38
114 SERIES
Caution: Before stamping the cylinder No. on the connecting rod, tighten the nut to the specified torque. When installing a new connecting rod, be sure to stamp the No. of the cylinder of the connecting rod to be replaced.
114 SERIES
15-39
INSPECTION OF CONNECTING RODS FOR BEND AND TORSION

CALIBRATION OF FIXING TOOL
Inspect each connecting rod for bend and torsion with the rod fixing tool (Part No. ST-561) and rod mandrel set (Part No. 3823386). Check that the distance between the centers is 215.975 mm 216.025 mm by using a new rod which has been measured. 5 Install the connecting rod cap as shown in Cleaning and inspection of connecting rods before reusing them. Install the piston pin mandrel of the rod inspecting mandrel kit (Part No. 3823286) into the hole of the piston pin. 5 If the piston pin housing has been removed, use the mandrel (3823283). If the former is still in the normal position, use the mandrel (Part No. 3823284). Insert and install the mandrel (Part No. 2823303) in the hole of the crankshaft and expand it. 5 Check that the pin on the mandrel is directed down and fixed to the center of the connecting rod. Insert and install the connecting rod in the rod fixing tool. Set the contact point of the dial indicator on the mandrel of the piston pin hole by moving the dial holder. Tighten the bracket to hold the dial indicator in position. Set the dial indicator and read the zero point. Turn the rod horizontally by 180 and set the connecting rod in the fixing tool again.
15-40
114 SERIES
Check the zero point of the dial indicator again. If the zero point of the dial indicator has changed, adjust the dial to the half of the reading. The fixing tool is calibrated now and the connecting rod can be set in it in either direction and the dial indicator indicates the same deflection on both sides of the zero point.
INSPECTION OF ALIGNMENT OF CONNECTING RODS

Check each connecting rod by inserting the mandrel and core in it. Set the connecting rod in the fixing tool.
Measure the length and bend (alignment) of the connecting rod. Length of connecting rod mm Min. 215.975 Max. 216.025 Bend (Alignment) of connecting rod mm When bushing is removed Max. 0.20 When bushing is fitted Max. 0.15
REPAIR PROCEDURE FOR CONNECTING RODS

Install a thickness gauge between the mandrel and the dial indicator holding plate as shown in the figure. Torsion of connecting rod When bushing is removed When bushing is fitted Max. Max. mm 0.50 0.30
114 SERIES
15-41
REPLACEMENT OF CONNECTING ROD BUSHINGS

Part No.3823690, Connecting Rod Pin Bore Bushing Removal/Installation Tool This tool used to remove and install the bushing to the correct position. Ref.No. (1) (2) (3) (4) (5) (6) Part No. 3823691 3823693 3823692 3823694 3823695 Qty Anvil 1 Cup 1 Mandrel 1 Driver Ring (Thick) 1 Knock-out-ring (Thinner) 1 Cotter Pin 1 Description
REMOVAL
Place the pin hole end of the connecting rod on the mandrel.
Place the kick-out ring (thinner ring) on the mandrel on the connecting rod top. Match the angled face.
Install a cup on the mandrel and secure it with a cotter pin.
15-42
114 SERIES
Install the mandrel in the base. Place the connecting rod so that its upper angle will be matched to the upper angle of the base. The connecting rod is placed on the level.
Apply force to the cup top to push out the connecting rod bushing.
Remove the cotter pin. Remove the cup and slide the connecting rod from the mandrel.
With the bushing removed, measure the inside diameter of the connecting rod bushing. 5 If the inside diameter of the connecting rod bushing is out of the specified range, replace the connecting rod. Inside diameter of pin hole of connecting rod (When bushing is removed) mm Min. 48.988 Max. 49.012
114 SERIES
15-43
INSTALLATION
Before installing the connecting rod bushing, soak it and the pin end of the connecting rod in clean engine oil 15W-40.
Place the connecting rod bushing on the mandrel.
Place the kick-out ring (thinner ring) inside the driver ring. Match the angle and set the angled side down. Matching the cut of the kick-out ring (thinner ring) to the pin of the driver ring, slide the ring over the mandrel.
Install the cap and secure it with the cotter pin.
15-44
114 SERIES
Insert the mandrel and its component parts in the chamfered side of the connecting rod. Match the angles of the bushing, connecting rod, and stop ring. 5 Any connecting rod is not chamfered double. It may be chamfered additionally so that the bushing can be installed easily. Do not chamfer the part in the bushing which is not supported, however.
Matching the oil hole in the bushing to the connecting rod (by using the groove in the mandrel), push the bushing in the pin hole of the rod until the mandrel and its component parts are in full contact. The contact maintains the alignment of the oil hole.
Place the connecting rod and mandrel assembly on the stand. The connecting rod is on the level when its upper angle is matched to the angle of the stand.
Apply force to the cup top to push the bushing in the connecting rod. Use a core or a press. Push in the bushing continuously until the driver ring comes in contact with the connecting rod.
114 SERIES
15-45
Inspect the alignment of the oil holes. A rod 3 mm (1/8 in.) in diameter must go through the oil holes (A) of the connecting rod and bushing freely. Inspect the clearance between the connecting rod bushing and connecting rod. Check that the bushing is installed to the correct position by using a thickness gauge of 0.025 mm. The thickness gauge of 0.025 mm must not go between the bushing and connecting rod (B).
Machining The inside of a new connecting rod bushing must be machined with a connecting rod boring machine, part No. 3823601 (Sunnen PM-300) or 3375144 (Tobin Arp). If adjusted normally, connecting rod boring machine Sunnen PM-300 or equivalent can maintain the all limit dimensions. 5 Do not use a honing machine of floating rod type.
INSPECTION
5 After each connecting rod is machined, all of its limit dimensions must be checked.
15-46
114 SERIES
REPLACEMENT OF VALVE INSERTS OF CYLINDER HEAD

REMOVAL
5 When both of a valve seat and a valve guide need to be replaced, install the valve guide first and finish the hole with a reamer.
Rotor (Part No. 3376405) and valve seat grooving kit (Part No. 3376407) Adjust the cutting depth to about 1.4 mm from the valve seat pocket.
Groove the valve seat. When turning the cutter motor in circumferential motion, set its base in parallel with the cylinder head.
Caution: If any chip or broken piece is caught between the cutter motor base and cylinder head, it can cause a serious damage.
114 SERIES
15-47
Cut to a sufficient depth so that the expanded seat pulling tool will be engaged fully with the groove.
Set the cutter motor so that the cutting tool will cut only the valve seat insert and will not enter the machined valve pocket of the cylinder head.
Slide hammer assembly (Part No. 33776617) Air intake valve seat pulling tool (Part No. 3377396) Exhaust valve seat pulling tool (Part No. ST-1276-1) Remove the valve seat insert.
Remove the all sediment from the valve seat insert hole with a wire brush and solvent. Clean the cylinder head with solvent, then dry it with compressed air.
15-48
114 SERIES
INSPECTION
Visually inspect the valve seat insert hole for cracking and damage. If the hole is cracked or damaged, replace the cylinder head.
Measure the inside diameter (A) and depth (B) of the valve seat insert in the cylinder head. Inside diameter (A) of insert hole (Standard insert) mm Air intake valve seat Max. 53.93 Exhaust valve seat Max. 47.03 Depth (B) of insert hole (Standard insert) mm Air intake valve seat Max. 12.20 Exhaust valve seat Max. 9.83 5 If either dimension does not satisfy the standard, replace the cylinder head.
ASSEMBLY
Cool the new valve seat inserts at 0C for 30 minutes before installing it so that they will be installed easily. Take the valve seat inserts out of the refrigerator one by one.
Install each valve insert with the chamfered part down. Drive each valve insert in the spot-faced part with the slide hammer assembly (Part No. 33776617) and a proper driver (See the special tools for the cylinder head). Check that the insert is in contact with the bottom of the spot-faced part.
114 SERIES
15-49
Grind the new valve seat insert with the valve seat grinder (Part No. ST-685), valve seat grinding core (Part No. 3823187), and a proper grindstone .
INSPECTION OF VALVE GUIDES

Visually inspect the valve guides for a scuff mark and a scratch. Measure the inside diameter of each valve guide at 13 mm from each end and at the center with a small inside diameter gauge as shown in the figure. Inside diameter of valve guide (when installed) (used one) mm Min. 9.539 Max. 9.591 Measure the installing height of the valve guide with a depth micrometer. Measure the distance from the valve guide top to the bottom of the spot-faced part. Height of valve guide (when installed) mm Air intake valve guide Min. 20.65 Max. 21.16 Exhaust valve guide Min. 22.50 Max. 23.01 If a valve guide is damaged or its dimensions do not satisfy the standard, replace it. See Replacement of cylinder valve guides.
15-50
114 SERIES
INSPECTION OF VALVE SEAT INSERTS

Visually inspect the valve seat inserts for cracking and seizure.
Measure the width of the valve seat zone of the valve seat insert. Valve seat zone (width) mm Min. 1.5 Max. 2.0 5 The sealing face of the valve must be at the center of the valve seat insert. If the valve seat zone is worn more than the standard value, see Grinding of valve seat inserts or Replacement of valve seat inserts of cylinder head. Gauge block (Part No. 3823495) Install each valve in the hole and measure the depth of its head from the cylinder head. Before measuring the depth of the valve head, check that the valve seat is clean. Depth of valve head from cylinder head mm Exhaust valve Min. 1.09 Max. 1.62 Air intake valve Min. 0.59 Max. 1.12 5 If the depth of a valve is out of the limits, replace that valve (A) with new one (B) before replacing the valve seat. If the depth of the new valve is in the limits, use that valve after grinding the used valve seat. See Grinding of valve seat inserts
114 SERIES
15-51
INSPECTION OF VALVE SPRINGS

Inspect the valve springs for damage (breakage, etc.)
Measure the valve springs. Free height of valve spring (A) mm Standard spring Air intake valve and exhaust valve Nominal value 65.66
Measure the load on each valve spring at the opening height with a valve spring tester (Part No. 3375182). Opening height B of valve spring mm Standard spring Nominal value 37.90
Load C on valve spring at opening height (new) N {kg} Standard spring Min. 960 {97.89} Air intake valve and exhaust valve Max. 1,060 {108.1} If the load on the valve spring at the opening height is less than the standard value, replace the valve spring.
15-52
114 SERIES
INSPECTION OF VALVE STEM SEAL

Visually inspect each valve spring retainer and valve stem seal for damage and wear. Remove the valve stem seal from the valve stem seal retainer and inspect it for damage or wear. Discard the all parts which cannot be reused.
INSPECTION OF VALVES
Visually inspect the valves for damage. If a valve has any of the following defects, replace it. Valve stem worn to below standard (A) Valve stem or sealing face rusted or pitted (B) Worn valve cotter groove (C)
Worn stem end (D) Bent valve stem (E) Damaged (Seized, cracked, or broken) valve head (F)
Measure the outside diameter of each valve stem. Diameter of valve stem mm Min. 9.46 Max. 9.50
114 SERIES
15-53
Valves having the following defects can be reused after ground. Fine grooves on valve seal surface (A) Fine pitting on valve seal surface (B) Carbon or varnish accumulated on valve stem (C)
GRINDING OF VALVES
Cleaning 5 The sealing surface of every valve to be reused must be finished by machining. Clean each valve stem with SCOTCH BRIGHT 7448 (Part No. 3823258). Remove the all carbon from the valve sealing surface and head. 5 Clean the valve and remove the all carbon from it before grinding its sealing surface. Grind the valve sealing surface with a valve face finisher (Part No. 3376256). 5 For preparation for grinding the valves, see the operation manual for the valve grinder.
Grind the air intake valves and exhaust valves to the following angles. Valve seat angle Valve Angle Air intake valve 30 Exhaust valve 45 Remove the all metallic particles from each valve with solvent, then dry the valve with compressed air.
15-54
114 SERIES
Place each valve on a flat place and measure thickness of its head at its periphery. Thickness of valve head (at periphery) mm Exhaust valve Min. 2.22 Air intake valve Max. 3.01 5 If the head of a valve is worn and thinner than the standard value, replace that valve.
Make marks on the valve seal face with a pencil as shown in the figure. Install the valve in the valve guide. Pressing the valve against the valve seat, rotate it forward and backward 3 4 turns. If the seal face is in contact with the valve seat normally, the marks on it are broken. 5 If the valve and valve seat are machined accurately, they do not need to be lapped with lapping compound. If lapping is required, inspect the conditions of the grinder and grindstone.
Install the all valves to the cylinder head. Perform the vacuum test on the valve seats with a valve vacuum tester (Part No. ST-1257). See Vacuum test on valve seats of cylinder head.
GRINDING OF VALVE SEAT INSERTS

5 If the inside of a valve guide is worn more than the limit, replace it before grinding the valve seal. When grinding the valve seat inserts, use valve seat grinder (Part No. ST-685) and valve guide core set (Part No. 3823187). Install valve guide core the valve guide. and core pulling tool to
Rotate the core to check that it is installed normally.
114 SERIES
15-55
Install valve seat grindstone 5
on the grinder.
The size and angle of the grindstone must be correct. (Air intake valve: 30, Exhaust valve: 45). Install the grinder on the core. 5 When the motor of the drive unit is installed, grindstone must not touch the valve seat insert. Holding the drive unit vertically and applying it to the seat lightly, move it up and down with the stroke of 12.7 mm to grind the seat.
Install eccentricity gauge (Part No. ST-685-4) to the core of the valve guide. Measure the concentricity of the valve seat and valve guide. Concentricity (in 360) mm Max. 0.05 5 If the concentricity of the valve seat does not satisfy the specification, grind the valve seat again. If the concentricity cannot satisfy the specification, replace the valve seat insert. See Replacement of valve seat inserts of cylinder head. Install the adjusted valves to the respective holes. Hold each valve on the valve seat insert side.
Gauge block (Part No. 3823495) Measure the depth of the valve in the cylinder head. Depth of valve from cylinder head mm Exhaust valve Min. 1.09 Max. 1.62 Air intake valve Min. 0.59 Max. 1.12
15-56
114 SERIES
If the depth of a valve is out of the limits, replace that valve (A) with new one (B) before replacing the valve seat. If the depth of the new valve is in the limits, use that valve and the used seat for the following procedure.
If the depth of new valve (B) is still out of the limits, replace valve seat (C) with new one (D). Then, measure the depth of used valve (A) again to see if it can be used again. If used valve (A) is cannot be used again, use new valve (B) for the following procedure. (A) = Used valve (B) = New valve (C) = Used valve seat insert (D) = New valve seat insert
Check that valve seat is in contact with the center of the valve seal face. Draw vertical lines on the valve seal face with a pencil.
Install the valve to the valve guide and hold it with the valve seat insert. Rotate the valve forward and backward 3 4 turns.
114 SERIES
15-57
Remove the valve and measure the valve seat width and the contact zone of the seat from the part where the vertical lines have disappeared. The vertical lines disappear from the part in contact with the seat. Limit width of valve seat mm Min. 1.5 Max. 2.0
Grind zone (A) of the valve seat insert with a 60 grindstone and zone (B) with a 15 grindstone, aligning them with the valve seat, to secure the width of the valve seat.
The position of the broken lines on the valve seal face is important to determination of how much the valve seat insert should be ground. If the lines are broken at the lower part of the seal face, grind the valve seat insert with the 60 grindstone rather than the 15 grindstone.
If the lines are broken at the upper part of the seal face, grind the valve seat insert with the 15 grindstone rather than the 60 grindstone.
15-58
114 SERIES
After grinding the valve seat insert, clean the inside of the valve guide with a hard brush. Clean the cylinder head with solvent, then dry it with compressed air.
ASSEMBLY
Installation of expansion plugs Apply plug seal in cup (Part No. 3375068) to the outside of the expansion plugs. 5 Install each expansion plug to the correct depth in the cylinder head with a correct expansion plug driver. Drive it until the shoulder of the driver comes in contact with the cylinder head. See the following table. Tool No. 3823522 3823524 3823522 3376815 5 Expansion plug No. 156075 3900965 3032693 3912900 Q'ty Location 1 A 2 B 5 C 1 D
If an air compressor is installed to the engine, do not use expansion plug (D). Instead, install a 90 elbow joint is installed as an air inlet. At this time, apply seal in cup (Part No. 3375068) and install the joint with the beaded end directed toward the lower 4 o'clock position.
INSTALLATION OF PIPE PLUGS

If the pipe plugs are not coated with sealant, apply plug sealant (Part No. 3375068) to their threads by 1 layer and install them according to the following table. Tightening torque Nm {kgm} 8 {0.8} 12 {0.12} 24 {2.4} 80 {8.0}
Location (A) (B) (C) (D) 5
Size 1/16 inch NPT 1/4 inch NPT 1/2 inch NPT Hexagon plug
Fit a copper seal washer to the hexagon plug (D).
114 SERIES
15-59
Clean the inside of the valve guide holes with a hard brush and blow off dust with compressed air.
Lubricate the valve guide holes and valve stems with engine oil SAE90W. Install the valves to the valve guides. The diameters of the exhaust valve heads are shorter. 5 5 When reusing a valve, install it to its original position. Each valve must fall in the valve guide without receiving any resistance. After installing the valves, place the cylinder head on a flat place where its surface will not be damaged.
Install the valve spring seats and valve seal assemblies on the valve stems. 5 Classify the seals by the color codes and install them as shown below to prevent carry-over of oil. Exhaust valve (A): Orange (Having 64 grooves in 25 mm) Air intake valve (B):Black (Having 40 grooves in 25 mm)
Install the valve springs. Install the valve spring retainers.
15-60
114 SERIES
Compress each valve spring with a valve spring compressor (Part No. ST-448) or equivalent (See the service tools list). Install valve cotter pin for the valve spring retainer. 5 When modifying the cylinder head, use a new valve cotter pin.
Warning:Put on an eye protector. If the valve cotter pin is not installed normally, it may jump out when the valve stem is hit with a hammer. Hit the valve stem top lightly with a plastic hammer and install the valve cotter pin in the spring retainer securely.
Perform the vacuum test on the valves with a valve vacuum tester (Part No. ST-1257). See Vacuum test on valve seats of cylinder head.
114 SERIES
15-61
REPLACEMENT OF VALVE GUIDES OF CYLINDER HEAD

DISASSEMBLY
5 The valve seats of the replaced valve guides must be ground. Remove used valve guide (Part No. 3823271). with valve guide driver
Clean the inside of the valve guide hole of the cylinder head with a hard brush and dry it with compressed air.
INSPECTION
Measure the inside diameter of the valve guide hole of the cylinder head. Inside diameter of valve guide hole mm Min. 15.931 Max. 15.971 If the diameter of the valve guide hole is longer than the specification value, replace the cylinder head.
ASSEMBLY
Measure the outside diameter of the new valve guide. Outside diameter of valve guide mm Min. 15.988 Max. 16.000
15-62
114 SERIES
The installing heights of the air intake valve and exhaust valve above the cylinder head top are different. For the correct fitting tools, see the following part No. Air intake valve:Part No. 3823269 Exhaust valve : Part No. 3823270 Drive the valve guide in the valve guide hole of the cylinder head until the driver comes in contact with the cylinder head.
Measure the installing height of the new valve guide above the cylinder head top deck with a depth micrometer. Installing height of valve guide mm Air intake valve Min. 20.65 Max. 21.16 Exhaust valve Min. 22.55 Max. 23.01
Valve guide reamer (Part No. 3822490) Ream the valve guide hole in only the fixed direction without lubricating the reamer. If the reamer is pulled back from the guide hole, the guide will be damaged.
Ream the valve guide hole again in only the fixed direction, lubricating the reamer with clean engine oil 15W-40.
114 SERIES
15-63
Clean the valve guide hole with a nylon brush and cleaning solvent.
Measure the inside diameter of the new valve guide at 13 mm from each end and at the center with a small inside diameter gauge as shown in the figure. Inside diameter of (new) valve guide (when installed) mm Min. 9.539 Max. 9.559 If the inside diameter of the valve guide hole is out of the specified range, replace the valve guide with new one.
15-64
114 SERIES
CYLINDER HEAD-PRESSURE TEST

Caution: Do not pressure test the cylinder head with the valves and valve springs installed. Water entering the cylinder head cannot be dried thoroughly and will damage the valve guides and valve stems.
A cylinder head test fixture can be fabricated from a flat piece of steel or aluminum. Refer to the following table for test fixture dimensions: Test fixture dimensions mm Length 851 Width 190 Thickness 16 5 Use the cylinder head gasket as a pattern for drilling the capscrew holes. Install the cylinder head water test fixture. Install a new head gasket Install the test plate Install the 26 cylinder head capscrew and M14 X 2.0 nuts
Tighten the nuts.
3 Nut: 45 Nm {4.5 kgm}
Connect a regulated air supply hose to the text fixture plate. Apply air pressure. Air Pressure: 276 kPa {27 kg/cm2} Use a nylon lifting strap and a hoist to place the cylinder head in a tank of heated water. Temperature: 60C Completely submerge the cylinder head in the water.
Visually inspect the water for bubbling. 114 SERIES
15-65
If any bubble is in the water, replace the cylinder head.
Remove the testing jig. Dry the cylinder head with compressed air. Assemble the cylinder head.
15-66
114 SERIES
VACUUM TEST ON VALVE SEATS OF CYLINDER HEAD

Inspect the sealing performance of the valves and valve seat inserts with a valve vacuum tester (Part No. ST-1257). 5 All the CUMMINS engine models can be tested with the above valve vacuum tester. The vacuum cup (Part No. ST-1257-6) can be used for the cylinder heads of the 114 Series engines.
Install a seal and the vacuum cup to the vacuum line (hose).
The valve and valve seat insert must be clean and dry when they take the vacuum test. Cover the valve with the cup and seal. 5 Set the seal around the valve of the cylinder head without making clearance.
Turn switch 5
ON. to the OPEN position.
Set vacuum control valve
If the vacuum gauge pointer moves clockwise, the vacuum control valve is at the OPEN position.
114 SERIES
15-67
Drive the vacuum pump until the gauge indicates the specified degree of vacuum. Vacuum in space between valve and valve seat kPa {mmHg} New Min. 67.7 {508} Max. 84.7 {635} Used Min. 60.9 {457} Turn switch OFF.
When the gauge pointer indicates 60.9kPa {457 mmHg}, start measuring the time with a stopwatch. When the gauge pointer indicates 27.1kPa {203 mmHg}, stop measuring the time. The measured time must be 10 seconds or longer.
If the measured time is shorter than 10 seconds, perform the following. Repeat the test and check that the equipment is operating normally. Hit the valve stem lightly with a wooden hammer and check that the valve is seated normally, then repeat the test. Apply grease thinly over the outside of the valve seat insert and valve head. Repeat the test. The grease pattern shows the leaking part.
Breakage of the grease pattern shows leakage between the valve and valve seat or between the valve seat insert and cylinder head.
15-68
114 SERIES
CLEANING AND INSPECTION OF CYLINDER HEAD BOLTS

Caution: Protect the bolts from being damaged. Breakage of the stem of a bolt can cause stress concentration which can cause an engine trouble. Damage of the threads of the bolt can cause wrong indication of the tightening torque and can damage the contact parts of the threads.
CLEANING
Caution: Do not use caustic or acid solutions to clean the cylinder head capscrews. Use a petroleum-based solvent to clean the capscrews. Clean the capscrews thoroughly with a wire brush, a soft wire wheel, or use a non-abrasive bead blast to remove deposits from the shank and threads.
INSPECTION
Visually inspect the cylinder head capscrews for damaged threads, corroded surfaces, or a reduced diameter (due to capscrew stretching). Caution: Do not reuse a capscrew that has damaged threads or a reduced diameter from having been stretched.
Do not reuse cylinder head capscrew under the following conditions: Visible corrosion or pitting exceeds 1cm2 in area. Example: Acceptable: 9.5 x 9.5 mm Unacceptable:12.7 x 12.7 mm
114 SERIES
15-69
Visible corrosion or pitting exceeds 0.12mm in depth. Visible corrosion or pitting is located within 3.2 mm of the fillet. Visible corrosion or pitting is located within 3.2 mm of the threads. Stretched beyond free length maximum. Refer to the measurement procedure bellow.
FREE LENGTH - MEASUREMENT

Part No. 3823921, Capscrews length gauge 5 If the capscrews are not damaged, they can be reused throughout the life of the engine unless the specified free length is exceeded. To check the capscrew free length, place the head of the capscrew in the appropriate slot with the flange against the base of the slot. Capscrew free length mm Short 81.5 Long 162.6
If the end of the capscrew touches the foot of the gauge, the capscrew is too long and must be discarded.
Immediately after cleaning and inspecting, apply a film of clean engine lubricating oil to all capscrews that are to be used again.
15-70
114 SERIES

114

Încărcat de

Informații document

Drepturi de autor

Formate disponibile

Partajați acest document

Partajați sau inserați document

Opțiuni de partajare

Vi se pare util acest document?

Este necorespunzător acest conținut?

Drepturi de autor:

Formate disponibile

114

Încărcat de

Drepturi de autor:

Formate disponibile

SEBM024603

2004 All Rights Reserved 114 SERIES Printed in Japan 03-04(03)

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD ............................................................11-1

TESTING AND ADJUSTING ..............................................................12-1

DISASSEMBLY AND ASSEMBLY ....................................................13-1

REPAIR AND REPLACEMENT OF PARTS ......................................15-1

Indication Page to be newly added Page to be replaced Page to be deleted

Action required Add Replace Discard

Pages having no marks are not revised at this time.

LIST OF REVISED PAGES

(3) (3) (3) z

(3) (3) (2) (2) (3) (2) (2)

(3) (1) (3) (3) (3) (2)

HOW TO READ THE SHOP MANUAL

HOW TO READ THE SHOP MANUAL

2) Sling wire ropes from the middle portion of the hook.

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

50 g Adhesive: 1 kg Hardening agent: 500 g 250 g 75 g

LT-3 Adhesives LT-4 Holtz MH 705 Three bond 1735

790-129-9060 (Set of adhesive and hardening agent) 790-129-9040 790-126-9120

Polyethylene container Tube Polyethylene container

Aron-alpha 201 Loctite 648-50 LG-1

Polyethylene container Polyethylene container Tube

LG-6 Gasket sealant LG-7

Three bond 1211 Three bond 1207B

Komatsu code LM-G

Part No. 09940-00051

Molybdenum disulphide lubricant

400 g 10 Bellows type 400 g 20 Bellows type 16 kg Can

Used for heavy load portion

Glass container Glass container

Polyethylene container Polyethylene container Polyethylene container

STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE

kgm 2.5 0.5 52 82 14 3 18 3 20 5 25 5 30 5

STANDARD TIGHTENING TORQUE

Width across flat mm 14 17 22 Nm 59 74 98 123 235 285

Tightening torque kgm 6 7.5 10 12.5 23.5 29.5

Thread diameter Norminal No. mm 02 03, 04 05, 06 10, 12 14 14 20 24 33 42

Width across flat mm

Varies depending on type of connector.

Thread diameter Norminal No. mm 08 10 12 14 16 18 20 24 30 33 36 42 52 08 10 12 14 16 18 20 24 30 33 36 42 52

Width across flat mm 14 17 19 22 24 27 30 32 32 36

STANDARD TIGHTENING TORQUE

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

ELECTRIC WIRE CODE

ELECTRIC WIRE CODE

2.4 3.1 4.6 7.0 11.4 13.6 17.6

12 20 37 59 135 178 230

CLASSIFICATION BY COLOR AND CODE

Color White & Blue Code WG

Black & Red Red & Yellow RG

0 0 10 20 30 40 A 50 60 70 80 90 0 0.394 0.787 1.181 1.575 1.969 2.362 2.756 3.150 3.543

0 0 10 20 30 40 50 60 70 80 90 0 0.394 0.787 1.181 1.575 1.969 2.362 2.756 3.150 3.543

0 0 10 20 30 40 50 60 70 80 90 0 22.05 44.09 66.14 88.18 110.23 132.28 154.32 176.37 198.42

1l = 0.2642 U.S. Gal

1l = 0.21997 U.K. Gal

CAPSCREW MARKINGS AND TORQUE VALUSES

CAPSCREW MARKINGS AND TORQUE VALUSES

CAPSCREW MARKINGS AND TORQUE VALUES - METRIC

Body Size Diam. Cast Iron

Torque Aluminum Cast Iron