Engine 114 - 2 Series Komatsu

SEBM024607
DIESEL ENGINE
2016
All Rights Reserved
114 SERIES
Printed in Japan 12-16 (01) 00-1
(7)
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
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following marks. It is requested that necessary
actions must be taken to these pages according to Q Page to be newly added Add
the list below.
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00-2-2 114 SERIES

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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 danger-
ous situation arises or may possibly arise, first consider safety, and take the necessary actions
to deal with the situation.
GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to keep

tools and removed parts. Always keep the tools
Mistakes in operation are extremely dangerous. and parts in their correct places. Always keep
Read the Operation and Maintenance Manual care- the work area clean and make sure that there is
fully BEFORE operating the machine. no dirt or oil on the floor. Smoke only in the areas
1. Before carrying out any greasing or repairs, read provided for smoking. Never smoke while work-
all the precautions given on the decals which are ing.
fixed to the machine.
2. When carrying out any operation, always PREPARATIONS FOR WORK
wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons 7. Before adding oil or making any repairs, park the
missing. machine on hard, level ground, and block the
Always wear safety glasses when hitting wheels or tracks to prevent the machine from
parts with a hammer. moving.
Always wear safety glasses when grinding 8. Before starting work, lower blade, ripper, bucket
parts with a grinder, etc. or any other work equipment to the ground. If
3. If welding repairs are needed, always have a this is not possible, insert the safety pin or use
trained, experienced welder carry out the work. blocks to prevent the work equipment from fall-
When carrying out welding work, always wear ing. In addition, be sure to lock all the control
welding gloves, apron, hand shield, cap and levers and hang warning signs on them.
other clothes suited for welding work. 9. When disassembling or assembling, support the
4. When carrying out any operation with two or machine with blocks, jacks or stands before
more workers, always agree on the operating starting work.
procedure before starting. Always inform your 10.Remove all mud and oil from the steps or other
fellow workers before starting any step of the places used to get on and off the machine.
operation. Before starting work, hang UNDER Always use the handrails, ladders or steps when
REPAIR signs on the controls in the operator's getting on or off the machine. Never jump on or
compartment. off the machine. If it is impossible to use the
5. Keep all tools in good condition and learn the handrails, ladders or steps, use a stand to pro-
correct way to use them. vide safe footing.
00-3
SAFETY SAFETY NOTICE
PRECAUTIONS DURING WORK 19.Be sure to assemble all parts again in their origi-
nal places.
11.When removing the oil filler cap, drain plug or Replace any damaged parts with new parts.
hydraulic pressure measuring plugs, loosen When installing hoses and wires, be sure
them slowly to prevent the oil from spurting out. that they will not be damaged by contact
Before disconnecting or removing components with other parts when the machine is being
of the oil, water or air circuits, first remove the operated.
pressure completely from the circuit. 20.When installing high pressure hoses, make sure
12.The water and oil in the circuits are hot when the that they are not twisted. Damaged tubes are
engine is stopped, so be careful not to get dangerous, so be extremely careful when install-
burned. ing tubes for high pressure circuits. Also, check
Wait for the oil and water to cool before carry- that connecting parts are correctly installed.
ing out any work on the oil or water circuits. 21.When assembling or installing parts, always use
13.Before starting work, remove the leads from the the specified tightening torques. When installing
battery. Always remove the lead from the nega- protective parts such as guards, or parts which
tive () terminal first. vibrate violently or rotate at high speed, be par-
14.When raising heavy components, use a hoist or ticularly careful to check that they are installed
crane. correctly.
Check that the wire rope, chains and hooks are 22.When aligning two holes, never insert your fin-
free from damage. gers or hand. Be careful not to get your fingers
Always use lifting equipment which has ample caught in a hole.
capacity. 23.When measuring hydraulic pressure, check that
Install the lifting equipment at the correct places. the measuring tool is correctly assembled before
Use a hoist or crane and operate slowly to pre- taking any measurements.
vent the component from hitting any other part.
24.Take care when removing or installing the tracks
Do not work with any part still raised by the hoist
of track-type machines.
or crane.
When removing the track, the track separates
15.When removing covers which are under internal suddenly, so never let anyone stand at either
pressure or under pressure from a spring, end of the track.
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.
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 judge-
ments. 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 fur-
ther 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 under-
standing of the structure, but also serves as reference material for troubleshooting.
In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and mainte-
nance 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 com-
ponent, 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 REVISED EDITION MARK
VOLUMES When a manual is revised, an edition mark

Shop manuals are issued as a guide to carrying out ((1)(2)(3)....) is recorded on the bottom of the pages.
repairs. They are divided as follows:
Chassis volume: Issued for every machine model REVISIONS

Engine volume: Issued for each engine series
Each issued as one Revised pages are shown in the LIST OF REVISED
Electrical volume:
}
Attachments volume: volume to cover all
models
PAGES next to the CONTENTS page.
SYMBOLS
These various volumes are designed to avoid dupli-
cating the same information. Therefore, to deal with So that the shop manual can be of ample practical
all repairs for any model , it is necessary that chas- use, important safety and quality portions are
sis, engine, electrical and attachment volumes be marked with the following symbols.
available.
DISTRIBUTION AND UPDATING

Any additions, amendments or other changes will be
sent to KOMATSU distributors. Get the most up-to- Symbol Item Remarks
date information before you start any work.
k
Special safety precautions
Safety are necessary when per-
forming the work.
FILING METHOD
1. See the page number on the bottom of the page. Special technical precau-
File the pages in correct order. tions or other precautions
2. Following examples show how to read the page a Caution for preserving standards
number. are necessary when per-
forming the work.
Example 1 (Chassis volume):
Weight of parts of sys-
10 - 3
4
tems. Caution necessary
Weight when selecting hoisting
Item number (10. Structure and wire, or when working pos-
Function) ture is important, etc.
Consecutive page number for each
3
Places that require special
item. Tightening
attention for the tightening
torque
torque during assembly.
Example 2 (Engine volume):
2
Places to be coated with
12 - 5 Coat adhesives and lubricants,
etc.
Unit number (1. Engine) Places where oil, water or
5
Item number (2. Testing and Adjust- Oil, water fuel must be added, and
ing) the capacity.
Consecutive page number for each
Places where oil or water
6
item.
Drain must be drained, and
quantity to be drained.
3. Additional pages: Additional pages are indicated
by a hyphen (-) and number after the page
number. File as in the example.
Example:
10-4 12-203
10-4-1 12-203-1
Added pages
10-4-2 12-203-2
10-5 12-204
00-6
FOREWORD HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
Slinging near the edge of the hook may cause

k Heavy parts (25 kg or more) must be lifted the rope to slip off the hook during hoisting, and
with a hoist, etc. In the DISASSEMBLY a serious accident can result. Hooks have max-
AND ASSEMBLY section, every part imum strength at the middle portion.
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 100% 88% 79% 71% 41%
part to the relative parts. SAD00479
2) Check for existence of another part causing
3) Do not sling a heavy load with one rope alone,
interference with the part to be removed.
but sling with two or more ropes symmetrically
wound onto the load.
k Slinging with one rope may cause turning
WIRE ROPES
1) Use adequate ropes depending on the
weight of parts to be hoisted, referring to of the load during hoisting, untwisting of
the table below: the rope, or slipping of the rope from its
original winding position on the load, which
Wire ropes can result in a dangerous accident.
(Standard "Z" or "S" twist ropes
without galvanizing) 4) Do not sling a heavy load with ropes forming a
wide hanging angle from the hook.
Rope diameter Allowable load
When hoisting a load with two or more ropes,
the force subjected to each rope will increase
mm kN tons with the hanging angles. The table below
shows the variation of allowable load kN {kg}
10 9.8 1.0 when hoisting is made with two ropes, each of
11.5 13.7 1.4 which is allowed to sling up to 9.8 kN {1000 kg}
12.5 15.7 1.6
vertically, at various hanging angles.
14 21.6 2.2
16 27.5 2.8
When two ropes sling a load vertically, up to
18 35.3 3.6 19.6 kN {2000 kg} of total weight can be sus-
20 43.1 4.4 pended. This weight becomes 9.8 kN {1000 kg}
22.4 54.9 5.6 when two ropes make a 120 hanging angle.
30 98.1 10.0 On the other hand, two ropes are subjected to
40 176.5 18.0 an excessive force as large as 39.2 kN {4000
50 274.6 28.0 kg} if they sling a 19.6 kN {2000 kg} load at a
60 392.2 40.0 lifting angle of 150.
The allowable load value is estimated to be one-

sixth 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
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
k Before carrying out the following work, release Type 1

the residual pressure from the hydraulic tank.
For details, see TESTING AND ADJUSTING,
Releasing residual pressure from hydraulic
tank.
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 hydrau-
lic 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 METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
Type 2 Type 3
1) Hold the mouthpiece of the tightening portion 1) Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end. the hexagonal portion at the male end.
2) Hold in the condition in Step 1), and turn 2) Hold in the condition in Step 1), and push
lever (4) to the right (clockwise). until cover (3) contacts contact surface a of
the hexagonal portion at the male end.
Disassembly
3) Hold in the condition in Steps 1) and 2), and 3) Hold in the condition in Steps 1) and 2), and
pull out whole body (2) to disconnect it. pull out whole body (2) to disconnect it.
Hold the mouthpiece of the tightening portion Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end to con- the hexagonal portion at the male end to con-
nect it. nect 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 Part No. Q'ty Container Main applications, featuresr
Used to prevent rubber gaskets, rub-

LT-1A 790-129-9030 150 g Tube ber cushions, and cock plug from
coming out.
Used in places requiring an immedi-
ately effective, strong adhesive.
20 g Polyethylene Used for plastics (except polyethyl-
LT-1B 790-129-9050 (2 pcs.) container ene, polyprophylene, tetrafluoroeth-
lene and vinyl chloride), rubber,
metal and non-metal.
Features: Resistance to heat and
Polyethylene chemicals
LT-2 09940-00030 50 g container Used for anti-loosening and sealant
purpose for bolts and plugs.
Adhesive: Used as adhesive or sealant for met-
790-129-9060 al, glass and plastic.
1 kg
(Set of adhesive
LT-3 Hardening Can
and hardening agent:
agent) 500 g
Adhesives
Polyethylene Used as sealant for machined holes.
LT-4 790-129-9040 250 g container
Holtz Used as heat-resisting sealant for re-

790-126-9120 75 g Tube pairing engine.
MH 705
Quick hardening type adhesive
Three bond Polyethylene Cure time: within 5 sec. to 3 min.
790-129-9140 50 g
1735 container Used mainly for adhesion of metals,
rubbers, plastics and woods.
Quick hardening type adhesive
Quick cure type (max. strength after
Aron-alpha Polyethylene
790-129-9130 2g 30 minutes)
201 container Used mainly for adhesion of rubbers,
plastics and metals.
Resistance to heat, chemicals
Loctite Polyethylene
79A-129-9110 50 cc Used at joint portions subject to high
648-50 container temperatures.
Used as adhesive or sealant for gas-
LG-1 790-129-9010 200 g Tube kets and packing of power train case,
etc.
Used as sealant for various threads,
pipe joints, flanges.
LG-5 790-129-9080 1 kg Can Used as sealant for tapered plugs,
elbows, nipples of hydraulic piping.
Features: Silicon based, resistance
to heat, cold
Used as sealant for flange surface,
LG-6 790-129-9020 200 g Tube tread.
Used as sealant for oil pan, final
Gasket drive case, etc.
sealant
Features: Silicon based, quick hard-
ening type
LG-7 790-129-9070 1g Tube Used as sealant for flywheel hous-
ing, intake manifold, oil an, thermo-
stat housing, etc.
Three bond Used as heat-resisting sealant for re-
790-129-9090 100 g Tube pairing engine.
1211
Features: Silicone type, heat resist-
ant, vibration resistant, and impact
Three bond 419-15-18131 100 g Tube resistant sealing material
1207B Used as sealing material for transfer
case
00-10
FOREWORD COATING MATERIALS
Category Komatsu code Part No. Q'ty Container Main applications, featuresr
Used as lubricant for sliding portion

LM-G 09940-00051 60 g Can (to prevent from squeaking).
Molybdenum Used to prevent seizure or scuffling
disulphide of the thread when press fitting or
lubricant LM-P 09940-00040 200 g Tube shrink fitting.
Used as lubricant for linkage, bear-
ings, etc.
SYG2-400LI General purpose type
SYG2-350LI
G2-LI SYG2-400LI-A Various Various
SYG2-160LI
SYGA-160CNLI
SYG2-400CA Used for normal temperature, light

SYG2-350CA load bearing at places in contact
G2-CA SYG2-400CA-A Various Various with water or steam.
SYG2-160CA
SYGA-160CNCA
Molybdenum Used for heavy load portion

SYG2-400M 400 g 10 Bellows type
disulphide
Grease SYG2-400M-A 400 g 20 Bellows type
grease SYGA-16CNM 16 kg Can
LM-G (G2-M)
Seizure resistance and heat resist-
Hyper White
Grease G2-T SYG2-400T-A ance higher than molybdenum di-
SYG2-16CNT 400 g Bellows type sulfide grease
G0-T (*) SYG0-400T-A (*) 16 kg Can Since this grease is white, it does
*: For use in cold SYG0-16CNT (*) not stand out against machine
district
body.
Biogrease G2B Since this grease is decomposed
SYG2-400B by bacteria in short period, it has
G2-BT (*) SYGA-16CNB 400 g Bellows type less effects on microorganisms,
*: For high SYG2-400BT (*) 16 kg Can animals, and plants.
temperature SYGA-16CNBT (*)
and large load
SUNSTAR Used as primer for cab side

Glass (Using limit: 4 months)
PAINT PRIMER 20 ml container
580 SUPER
Primer
SUNSTAR Used as primer for glass side
Glass (Using limit: 4 months)
GLASS PRIMER 20 ml container
580 SUPER 417-926-3910
Adhesive for cab glass
"S" is used for high-tempera-

SUNSTAR ture season (April - October)
PENGUINE Polyethylene and "W" for low-temperature
SEAL 580 320 ml container season (November - April) as
SUPER "S" or
Adhesive adhesive for glass.
"W" (Using limit: 4 months)
Sika Japan, Polyethylene Used as adhesive for glass.
20Y-54-39850 310 ml (Using limit: 6 months)
Sikaflex 256HV container
SUNSTAR Used to seal joints of glass

Polyethylene parts.
PENGUINE 417-926-3920 320 ml container (Using limit: 4 months)
SEAL No. 2505
Caulking
material Used to seal front window.
SEKISUI Polyethylene (Using limit: 6 months)
SILICONE 20Y-54-55130 333 ml container
SEALANT
00-11
FOREWORD STANDARD TIGHTENING TORQUE
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 Width across
of bolt flats
mm mm Nm kgm
6 10 11.8 14.7 1.2 1.5

8 13 27 34 2.8 3.5
10 17 59 74 6 7.5
12 19 98 123 10 12.5
14 22 153 190 15.5 19.5
16 24 235 285 23.5 29.5

18 27 320 400 33 41
20 30 455 565 46.5 58
22 32 610 765 62.5 78
24 36 785 980 80 100
27 41 1150 1440 118 147

30 46 1520 1910 155 195
33 50 1960 2450 200 250
36 55 2450 3040 250 310
39 60 2890 3630 295 370
Tightening torque
Thread diameter Width across
of bolt flats
mm mm Nm kgm
6 10 5.9 9.8 0.6 1.0

8 13 13.7 23.5 1.4 2.4
10 14 34.3 46.1 3.5 4.7
12 27 74.5 90.2 7.6 9.2
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. SAD00483
Thread diameter Width across flat Tightening torque
mm mm Nm kgm
14 19 24.5 4.9 2.5 0.5

18 24 49 19.6 52
22 27 78.5 19.6 82
24 32 137.3 29.4 14 3
30 36 176.5 29.4 18 3
33 41 196.1 49 20 5
36 46 245.2 49 25 5
42 55 294.2 49 30 5
00-12
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 Width across flat Tightening torque
mm mm Nm kgm
10 14 59 74 6 7.5
12 17 98 123 10 12.5
16 22 235 285 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 Width across flat Tightening torque (Nm {kgm})

Norminal No.
mm mm Range Target
02 14 35 63 {3.5 6.5} 44 {4.5}

03, 04 20 Varies depending 84 132 {8.5 13.5} 103 {10.5}
05, 06 24 on type of 128 186 {13.0 19.0} 157 {16.0}
10, 12 33 connector. 363 480 {37.0 49.0} 422 {43.0}
14 42 746 1010 {76.0 103} 883 {90.0}
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 Width across flat Tightening torque (Nm {kgm})

Norminal No.
mm mm Range Target
08 08 14 5.88 8.82 {0.6 0.9} 7.35 {0.75}

10 10 17 9.8 12.74 {1.0 1.3} 11.27 {1.15}
12 12 19 14.7 19.6 {1.5 2.0} 17.64 {1.8}
14 14 22 19.6 24.5 {2.0 2.5} 22.54 {2.3}
16 16 24 24.5 34.3 {2.5 3.5} 29.4 {3.0}
18 18 27 34.3 44.1 {3.5 4.5} 39.2 {4.0}
20 20 30 44.1 53.9 {4.5 5.5} 49.0 {5.0}
24 24 32 58.8 78.4 {6.0 8.0} 68.6 {7.0}
30 30 32 93.1 122.5 {9.5 12.5} 107.8 {11.0}
33 33 107.8 147.0 {11.0 15.0} 124.4 {13.0}
36 36 36 127.4 176.4 {13.0 18.0} 151.9 {15.5}
42 42 181.3 240.1 {18.5 24.5} 210.7 {21.5}
52 52 274.4 367.5 {28.0 37.5} 323.4 {33.0}
00-13
TIGHTENING TORQUE FOR 102 ENGINE SERIES

1) BOLT AND NUTS
Use these torques for bolts and nuts (unit: mm) of Cummins Engine.
Thread diameter Tightening torque
mm Nm kgm
6 10 0 2 1.02 0 0.20
8 24 0 4 2.45 0 0.41
10 43 0 6 4.38 0 0.61
12 77 0 12 7.85 0 1.22
2) EYE JOINTS
Use these torques for eye joints (unit: mm) of Cummins Engine.
mm Nm kgm
6 802 0.81 0 0.20
8 10 0 2 1.02 0 0.20
10 12 0 2 1.22 0 0.20
12 24 0 4 2.45 0 0.41
14 36 0 5 3.67 0 0.51
3) TAPERED SCREWS
Use these torques for tapered screws (unit: inch) of Cummins Engine.
inch Nm kgm
1 / 16 301 0.31 0 0.10
1/8 802 0.81 0 0.20
1/4 12 0 2 1.22 0 0.20
3/8 15 0 2 1.53 0 0.41
1/2 24 0 4 2.45 0 0.41
3/4 36 0 5 3.67 0 0.51
1 60 0 9 6.12 0 0.92
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.
Taper seal
Tightening torque (Nm {kgm}) Face seal type
type
Nominal size Width across
of hose flats Nominal thread
Thread size size Root diameter
Range Target - Threads per
(mm) inch, Thread series (mm) (Reference)
9
02 19 34 - 63 {3.5 - 6.5} 44 {4.5} 14 - 18UNF 14.3
16
11
22 54 - 93 {5.5 - 9.5} 74 {4.5} - 16UN 17.5
03 16
24 59 - 98 {6.0 - 10.0} 78 {8.0} 18
13
04 27 84 - 132 {8.5 - 13.5} 103 {10.5} 22 - 16UN 20.7
16
05 32 128 - 186 {13.0 - 19.0} 157 {16.0} 24 1 - 14UNS 25.4
3
06 36 177 - 245 {18.0 - 25.0} 216 {22.0} 30 1 - 12UNF 30.3
16
(10) 41 177 - 245 {18.0 - 25.0} 216 {22.0} 33
(12) 46 197 - 294 {20.0 - 30.0} 245 {25.0} 36
(14) 55 246 - 343 {25.0 - 35.0} 294 {30.0} 42
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 Cable O.D. Current
number Dia. of Cross (mm) rating Applicable circuit
Number of strands section (A)
strands (mm2) (mm2)
0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal

etc.
2 26 0.32 2.09 3.1 20 Lighting, signal etc.
5 65 0.32 5.23 4.6 37 Charging and signal
15 84 0.45 13.36 7.0 59 Starting (Glow plug)
40 85 0.80 42.73 11.4 135 Starting
60 127 0.80 63.84 13.6 178 Starting
100 217 0.80 109.1 17.6 230 Starting
CLASSIFICATION BY COLOR AND CODE
Circuits
Priori- Charging Ground Starting Lighting Instrument Signal Other
ty Classi-
fication
Code W B B R Y G L
Pri-
1 mary
Color White Black Black Red Yellow Green Blue
Code WR BW RW YR GW LW
2
Color White & Red White & Black Red & White Rellow & Red Green & White Blue & White
Code WB BY RB YB GR LR
3
Color White & Black Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow
Code WL BR RY YG GY LY
Auxi-
4 liary Yellow & Green &
Color White & Blue Black & Red Red & Yellow Blue & Yellow
Green Yellow
Code WG RG YL GB LB
5
Color White & Green Red & Green Yellow & Blue Green & Black Blue & Black
Code RL YW GL n
6
Color Red & Blue Yellow & White Green & Blue 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 mil-
limeters 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.
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
C
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
A 50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
00-16
Millimeters to Inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to Pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84

10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
00-17
Liter to U.S. Gallon

1l = 0.2642 U.S. Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378

10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
Liter to U.K. Gallon

1l = 0.21997 U.K. Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980

10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.969 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
00-18
kgm to ft. lb
1 kgm = 7.233 ft. lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1

10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
00-19
kg/cm2 to lb/in2
1kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0

10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
00-20
Temperature
Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Cen-
tigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface col-
umn 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 F C F C F C F
40.4 40 40.0 11.7 11 51.8 7.8 46 114.8 27.2 81 117.8

37.2 35 31.0 11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
34.4 30 22.0 10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
31.7 25 13.0 10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
28.9 20 4.0 9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
28.3 19 2.2 8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

27.8 18 0.4 8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
27.2 17 1.4 7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
26.7 16 3.2 7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
26.1 15 5.0 6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
25.6 14 6.8 6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

25.0 13 8.6 5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
24.4 12 10.4 5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
23.9 11 12.2 4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
23.3 10 14.0 3.9 25 77.0 15.6 0 140.0 35.0 95 203.0
22.8 9 15.8 3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

22.2 8 17.6 2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
21.7 7 19.4 2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
21.1 6 21.2 1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
20.6 5 23.0 1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
20.0 4 24.8 0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

19.4 3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
18.9 2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
18.3 1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
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 cap-
screw.
The following examples indicate how capscrews are identified:

Metric - M8 - 1.25 X 25 U.S. Customary (5/16 X1 8 X 1-1/2)
M8 1.25 25 M8 1.25 25
Major Distance Major
Length Number Length
Thread Between Thread
in Threads in
Diameter in Threads in Diameter
Millimeters per Inch Inches
Millimeters Millimeters in Inches
NOTES:
1. Always use the torque values listed in the following tables when specific torque values are not available.
2. Do not use the torque values in place of those specified in other sections of this manual.
3. The torque values in the table are based on the use of lubricated threads.
4. 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.
114 SERIES 00-23

CAPSCREW MARKINGS AND TORQUE VALUES - METRIC
Commercial Steel Class

8.8 10.9 12.9
Capscrew Head Markings
Body
Torque Torque Torque
Size
Diam. Cast Iron Aluminum Cast Iron Aluminum Cast Iron 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 0.92 9 5 0.71 7 4 1.2 12 9 0.71 7 4 1.4 14 9 0.71 7 4

7 1.4 14 9 1.1 11 7 1.8 18 14 1.1 11 7 2.3 23 18 1.1 11 7
8 2.5 25 18 1.8 18 14 3.4 33 25 1.8 18 14 4.1 40 29 1.8 18 14
10 4.6 45 33 3.1 30 25 6.1 60 45 3.1 30 25 7.1 70 50 3.1 30 25
12 8.2 80 60 5.6 55 40 10.7 105 75 5.6 55 40 12.7 125 95 5.6 55 40
14 12.7 125 90 9.2 90 65 16.8 165 122 9.2 90 65 19.9 195 145 9.2 90 65
16 18.4 180 130 14.3 140 100 24.5 240 175 14.3 140 100 29.6 290 210 14.2 140 100
18 23.5 230 170 18.4 180 135 32.6 320 240 18.4 180 135 40.8 400 290 18.4 180 135
00-24 114 SERIES

1
CAPSCREW MARKINGS AND TORQUE VALUES - U.S. CUSTOMARY
SAE grade number 5 8
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 Aluminum Cast Iron Aluminum
mm kgm Nm ft-lb kgm Nm ft-lb kgm Nm ft-lb kgm Nm ft-lb
1/4 - 20 0.92 9 7 0.82 8 6 1.5 15 11 0.82 8 6

- 28 1.2 12 9 0.92 9 7 1.8 18 13 0.92 9 7
5/16 - 18 2.0 20 15 1.6 16 12 3.1 30 22 1.6 16 12
- 24 2.3 23 17 1.9 19 14 3.4 33 24 1.9 19 14
3/8 - 16 4.1 40 30 2.5 25 20 5.6 55 40 2.5 25 20
- 24 4.1 40 30 3.6 35 25 6.1 60 45 3.6 35 25
7/16 - 14 6.1 60 45 4.6 45 35 9.2 90 65 4.6 45 35
- 20 6.6 65 50 5.6 55 40 9.7 95 70 5.6 55 40
1/2 - 13 9.7 95 70 7.6 75 55 13.3 130 95 7.6 75 55
- 20 10.2 100 75 8.2 80 60 15.3 150 110 8.2 80 60
9/16 - 12 13.8 135 100 11.2 110 80 19.4 190 140 11.2 110 80
- 18 15.3 150 110 11.7 115 85 21.4 210 155 11.7 115 85
5/8 - 11 18.4 180 135 15.3 150 110 26 255 190 15.3 150 110
- 18 21.4 210 155 16.3 160 120 29.6 290 215 16.3 160 120
3/4 - 10 33.1 325 240 26 255 190 46.9 460 340 26 255 190
- 16 37.2 365 270 29.1 285 210 52.5 515 380 29.1 285 210
7/8 - 9 50 490 360 38.7 380 280 76 745 550 38.7 380 280
- 14 54 530 390 42.8 420 310 84.1 825 610 42.8 420 310
1-8 73.4 720 530 58.1 570 420 112.2 1100 820 58.1 570 420
- 14 81.6 800 590 66.3 650 480 122.4 1200 890 66.5 650 480
114 SERIES 00-25

1
FOREWORD PIPE PLUG TORQUE VALUES
PIPE PLUG TORQUE VALUES
Size Torque Torque
Actual
Thread In Aluminum Components In Cast Iron or Steel Components
Thread O.D.
in in kgm Nm ft-lb kgm Nm ft-lb

1/16 0.32 0.51 5 45 in-lb 1.5 15 10
1/8 0.41 1.5 15 10 2.0 20 15
1/4 0.54 2.0 20 15 2.5 25 20
3/8 0.68 2.5 25 20 3.7 35 25
1/2 0.85 3.7 35 25 5.6 55 40
3/4 1.05 4.6 45 35 7.6 75 55
1 1.32 6.1 60 45 9.7 95 70
1 - 1/4 1.66 7.6 75 55 11.7 115 85
1 - 1/2 1.90 8.7 85 65 13.8 135 100
00-26 114 SERIES

FOREWORD SYMBOLS
SYMBOLS
The following symbols have been used in this man-
ual to help communicate the intent of the instruc-
tions. 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 MEA-

SUREMENT.
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 informa-
tion.
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 prob-
lem, 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-chas-
sis". 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. Applicable machine
PC300-7 Hydraulic excavator
WA380-5 Wheel loader

SAA6D114E-2
GD655-3A,3C Motor grader
GD675-3A,3C Motor grader
CD110R-2 Crawler carrier
D63E-12 (For Russia)

SA6D114E-2 Bulldozer
D68ESS-12E0
01-2 114 SERIES

(6)
This Page Intentionally left Blank
GENERAL SPECIFICATION
SPECIFICATION
Engine SAA6D114E-2
Applicable model PC300-7 WA380-5 GD655-3A,3C
No. of cylinders - Bore x Stroke mm 6 - 114 x 135

Total piston displacement {cc} 8.27 {8.268}
Firing order 1-5-3-6-2-4
Overall length mm 1,615 1,166 1,130
Overall width mm 825 906 747
Dimensions
Overall height mm 1,300 1,632 1,418

(excluding exhaust pipe)
Overall height mm
(including exhaust pipe)
Flywheel horsepower kW/rpm 180/1,900 140/2,000 147/1,900
{HP/rpm} {242/1,900} {190/2,000} {197/1,900}
(Net) (Net) (Gross)
Max. torque Nm/rpm 1,080/1,400 883/1,400 940/1,400
{kgm/ {110/1,400} {90/1,400} {96/1,400}
Performance
rpm} (Net) (Net) (Gross)

2,16050 2,23050 2,22550
High idling speed rpm
90025 850+50 82550
Low idling speed rpm 0
Min. fuel consumption g/kWh 213 204 213

ratio {g/HPh} {159} {152} {159}
Dry weight kg 860 870 750
Fuel injection pump BOSCH P3000 type
Governor centrifugal, all speed type
Lubricating oil amount 40 37 24
(refil capacity) (35) (32) (19)
Coolant amount 9.8 (engine only) 9.8 (engine only) 9.8 (engine only)
Alternator 24V, 35A 24V, 60A 24V, 60A or 24V, 90A
Starting motor 24V, 7.5Kw 24V, 7.5Kw 24V, 7.5Kw or 24V, 11Kw
Battery 12V, 108Ah x 2 12V, 150Ah x 2 12V, 150Ah x 2
Turbocharger HOLSET HX40W HOLSET HX40W HOLSET HX40W
Air compressor
Others with air cooled with air cooled with air cooled
aftercooler aftercooler aftercooler
01-4 114 SERIES

(3)
GENERAL SPECIFICATION
SAA6D114E-2 SA6D114E-2
D63E-12
GD675-3A,3C CD110R-2 D68ESS-12E0
(For Russia)
6 114 x 135 6 114 x 135 6 114 x 135
8.27 {8.268} 8.27 {8.268} 8.27 {8.268}
1-5-3-6-2-4 1-5-3-6-2-4 1-5-3-6-2-4
1,130 1,405 1,097 1,097
747 987 768 768
1,418 1,392 1,181 1,181

154/1,900 180/1,900 126.7/1,800 126.7/1,800
{206/1,900} {242/1,900} {170/1,800} {170/1,800}
(Gross) (Net) (Gross) (Gross)
989/1,400 1,080/1,400 853/1,300 853/1,300
{101/1,400} {110/1,400} {87/1,300} {87/1,300}
(Gross) (Net) (Gross) (Gross)
2,225 50 2,160 50 2,000 50 2,000 50
825 50 900 25 915 50 915 50
215 213 226 (at rated point) 226 (at rated point)
{160} {160} {116} {166}
750 850 749 749
BOSCH P3000 type BOSCH AD
centrifugal, all speed type centrifugal, all speed type
24 24 30.5 30.5
(19) (19) (25.5) (25.5)
9.8 (engine only) 9.8 (engine only) 9.8 (engine only) 9.8 (engine only)
24V, 60A or 24V, 90A 24V, 35A 24V, 35A 24V, 35A
24V, 7.5Kw or 24V, 11Kw 24V, 7.5Kw 24V, 11Kw 24V, 7.5Kw
12V, 150Ah x 2 12V, 108Ah x 2 12V, 140Ah x 2 12V, 112Ah x 2
HOLSET HX40W HOLSET HX40W HOLSET HX40 HOLSET HX40

with air cooled with air cooled

aftercooler aftercooler
114 SERIES 01-5

(6)
GENERAL OVERALL DRAWING
OVERALL DRAWING
The diagram shows the equipment for the PC300-7.
The shape may differ according to the machine model.
SAA6D114E-2 LEFT SIDE DRAWING
a. Crankshaft center
b. Flywheel housing rear surface
01-20 114 SERIES

(2)
SAA6D114E-2 FRONT DRAWING

The diagram shows the equipment for the PC300-7.
b. Cylinder liner center
114 SERIES 01-21

(2)
SA6D114E-2 LEFT SIDE DRAWING

The diagram shows the equipment for the D63E-12 (For Russia).
b. Flywheel housing rear surface
01-21-1 114 SERIES

(5)
SA6D114E-2 FRONT DRAWING

The diagram shows the equipment for the D63E-12 (For Russia).
b. Cylinder liner center
114 SERIES 01-21-2

(5)
DIMENSION TABLE H These dimensions are reference values for use

when installing to a test bench.
(Unit: mm)
Dimensions for each part
Engine Machine model
A B C D E F G
PC300-7 1,357 1,300 856 444 480 345 258
WA380-5 1,166 1,632 1,235 397 445 461
SAA6D114E-2 GD655-3A,3C 1,130 1,418 1,093 325 424 423
GD675-3A,3C 1,130 1,418 1,093 325 424 423
CD110R-2 1,357 1,392 992 400 619 368 48
D63E-12
SA6D114E-2 (For Russia) 1,097 1,181 797 384 380 377
D68ESS-12E0
01-22 114 SERIES

1
(6)
GENERAL WEIGHT TABLE
WEIGHT TABLE
(Unit: kg)
No. Item Main component SAA6D114E-2 SA6D114E-2
1 Turbocharger
Cylinder head Cylinder head, valve

2 assembly rocker arm, valve
spring
Cylinder block Cylinder block, bear-

3
assembly ing cap
4 Front cover
5 Oil pan
6 Flywheel assembly Flywheel, ring gear
7 Flywheel housing
Crankshaft Crankshaft, Crank-

8
assembly shaft gear
Camshaft assembly Camshaft, Camshaft

9
gear, thrust plate
Piston, connecting PIston, piston ring,

10 rod assembly piston pin, connect-
ing rod
11 Oil pump
12 Fuel injection pump BOSCH type
13 Water pump
14 Alternator
15 Starting motor
16 Aftercooler assembly
114 SERIES 01-31

(5)
GENERAL ENGINE PERFORMANCE CURVE
ENGINE PERFORMANCE CURVE
Engine Engine Serial No. Machine model Page
PC300-7, CD110R-2 01-33

WA380-5 01-34
SAA6D114E-2
GD655-3A,3C 01-35
GD675-3A,3C 01-36
SA6D114E-2 01-37
D68ESS-12E0
01-32 114 SERIES

(6)
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)
SAA6D114E-2 (WA380-5)
Flywheel horsepower : 151.5kW {203HP}/2,000rpm (Gross)
Maximum torque : 945Nm {96.4kgm}/1,400rpm (Gross)
01-34 114 SERIES

1
SAA6D114E-2 (GD655-3A,3C)
Flywheel horsepower : 147kW {197HP}/1,900rpm (Gross)
Maximum torque : 940Nm {96kgm}/1,400rpm (Gross)
114 SERIES 01-35

(2)
SAA6D114E-2 (GD675-3A,3C)
Flywheel horsepower : 154kW {206HP}/1,900rpm (Gross)
Maximum torque : 989Nm {101kgm}/1,400rpm (Gross)
01-36 114 SERIES

(2)
SA6D114E-2 (D63E-12, D68ESS-12E0)

Flywheel horsepower : 126.7 kW {170 HP} / 1,800 rpm (Gross)
Maximum torque : 853 Nm {87 kgm} / 1,300 rpm (Gross)
114 SERIES 01-37

(6)
11 STRACTURE AND FUNCTION
AIR INTAKE DEVICE ............................................11-2 FLYWHEEL, FLYWHEEL HOUSING ................... 11-52

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

(2)
STRUCTURE AND FUNCTION AIR INTAKE DEVICE
AIR INTAKE DEVICE
SAA6D114E-2 The shape may differ according to the machine it

is mounted on.
1 Air connector A: Air supply inlet

2 Electrical intake air heater B: Front face of cylinder block
3 Cylinder head (forms one unit with intake mani-
fold)
4 Muffler
5 Exhaust pipe
6 Exhaust pipe (turbocharger - muffler)
7 Turbocharger
8 Exhaust manifold
11-2 114 SERIES

114 SERIES 11-3

OUTLINE OF INTAKE AND EXHAUST SYS- Note: The turbocharger is a high-performance

product, so do not touch or adjust it unless
TEM
necessary. The exhaust bracket forms one
unit with the turbocharger. If the exhaust
This engine is equipped with a turbocharger and air-
components are touched unnecessarily,
cooled aftercooler.
the pressure in the intake and exhaust
The air passes through the air cleaner and is sucked
manifolds will become part of adjustment,
into the engine. This air must be clean to ensure the
and the cylinder pressure and heat load
service life of the engine. If dirt or dust is sucked in,
will increase, so the durability will drop.
it will immediately damage the cylinders.
The fuel consumption will increase and the
Always use a high-quality air cleaner and clean or
exhaust system will no longer conform to
replace the air cleaner element according to the pro-
the exhaust regulations. Even if the turbo-
cedures specified in the Operation and Maintenance
charger boost is raised, the engine output
Manual.
will not increase.
The air sucked into an engine with turbocharger and
The terminal, compressor wheel, and shaft are sup-
air-cooled aftercooler is sucked in from the air
ported by the bearing housing with two roller bear-
cleaner through the compressor side of the turbo-
ings. The passage inside the bearing housing is
charger. It is sent from the turbocharger, passes
directly filtered, and the engine oil is pressurized
through the cooling fins of the air-cooled aftercooler,
against the shaft bearing and thrust bearing. The oil
and is then sent from the intake manifold to the cyl-
is used for lubricating and cooling the rotating com-
inder, where it is used for combustion. The exhaust
ponents to allow them to move smoothly. The oil is
gas flows to the exhaust side of the turbocharger,
drained from the bearing housing through the oil
and the energy of the exhaust gas is used to drive
drain line, and drops into the oil pan. If there is
the turbine wheel. The turbine wheel and the shaft
resistance or damage in the drain line, the turbo-
drive the compressor wheel and send large amounts
charger bearing housing will be pressurized, and
of air to the cylinder for combustion. If the amount of
this will cause leakage of oil from the seal.
air sent by the turbocharger is increased, it is possi-
Note: An ample supply of good quality filtered oil
ble to increase the amount of fuel injected, and this
is necessary to ensure the service life of
increases the engine output. If it is also cooled, the
the turbocharger. Always use high-quality
density of the air is increased, and more oxygen is
oil and change the oil and oil filters accord-
supplied, so the amount of fuel injected can be fur-
ing to the specified maintenance proce-
ther increased to increase the output of the engine.
dures.
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.
11-4 114 SERIES

STRUCTURE AND FUNCTION EXHAUST MANIFOLD
EXHAUST MANIFOLD
Unit:mm
No. Check item Criteria Remedy
Flatness of exhaust manifold

1 0.20
mounting surface
Flatness of turbocharger Replace
2 charger mounting flange 0.13

surface
114 SERIES 11-5

STRUCTURE AND FUNCTION AIR CLEANER
AIR CLEANER
FRG TYPE (CYCLOPACK TYPE)

FRG TYPE (RADIAL SEAL TYPE) The shape may differ according to the machine it
is mounted on.
1. Outlet 4. Outer element 7. Vacuator valve

2. Inlet 5. Inner element
3. Body 6. Latch
Engine Machine model Type Actuator valve No. of elements

PC300-7
WA380-5
Inner element x 1,
SAA6D114E-2 GD655-3A,3C FRG (Radial seal type) Automatic discharge
outer element x 1
GD675-3A,3C
CD110R-2
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 ele-
ment 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 evacu-
ator valve (7), and then they are discharged automatically.
11-6 114 SERIES
(3)
STRUCTURE AND FUNCTION TURBOCHARGER
TURBOCHARGER
SAA6D114E-2
1 Retainer
15 Adapter Specifications
2 Blower housing 16Turbine impeller Type: Holsett HX40W
3 O-ring 17Piston ring
4 Piston ring 18Shroud (heat shield) Applicable exhaust temperature:
5 Slinger 19Gasket Max. 700C (inlet port)
6 Locknut 20Turbine housing Direction of rotation: Clockwise
7 Blower impeller 21Plate (as seen from blower)
8 Retainer 22Actuator
9 Baffle oil A. Intake inlet port
10Thrust bearing B. Air supply outlet port
11Thrust collar C. Exhaust inlet port
12Center housing D. Exhaust outlet port
13Journal bearing E. Oil inlet port
14Retainer F. Oil outlet port
114 SERIES 11-7

OUTLINE OF WASTE GATE VALVE
This maintains a suitable supercharging pres-

sure (set supercharging pressure) in order to
prevent any excessive load on the engine by
suppressing any supercharging above the nec-
essary 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 com-
pressor 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 supercharg-
ing pressure b intersect is the point where the
waste gate valves start to open.
Pressure (A) near the outlet port of the compres-

sor 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

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

TURBO CHARGER
11-10 114 SERIES

Unit:mm
Play in radial direction of

1 A 0.33~0.50 Repair or
rotor
replace
2 Play in axial direction of rotor B 0.03~0.09
ightening torque of turbine

3 14Nm {1.4kgm} Tighten
housing bolt
Outside diameter of wheel

C 10.97~10.98
4 shaft
Curvature of wheel shaft Repair limit: 0.008 (total movement of indicator)

Replace
5 Inside diameter of back plate 19.305~19.330
Inside diameter of center D 15.875~15.885

6
housing E 19.305~19.330
114 SERIES 11-11

STRUCTURE AND FUNCTION AFTERCOOLER
AFTERCOOLER
AIR-COOLED TYPE
SAA6D114E-2
The shape may differ according to the machine it
is mounted on.
1. Side support A: From turbocharger

2. Tube B: To intake manifold
3. Fin
4. Tank
11-12 114 SERIES

1
STRUCTURE AND FUNCTION CYLINDER HEAD
CYLINDER HEAD
SAA6D114E-2
The shape may differ according to the machine it is mounted on.
1. Cylinder head 8. Valve insert (intake side)

2. Head cover 9. Valve insert (exhaust side)
3. Breather
4. Oil filler cap
5. Head bolt
6. Nozzle holder
7. Gasket
11-14 114 SERIES

Specifications
Head cover Valve seat
Float mount type Intake side: Insert press fitted
Exhaust side: Insert press fitted
Cylinder head
Direct injection type
Monocoque type
2 valve (1 cylinder)
Injection nozzle mount: Dry type (no sleeve)
114 SERIES 11-15

CYLINDER HEAD
11-16 114 SERIES

Unit:mm
Vertical
0.20 Repair by
Distortion of cylinder head direction
1 grinding or
mounting surface Lateral
0.76 replace
direction
Step Tightening torque
1st step: All 70Nm {7.1kgm}

Tightening torque of cylinder
2nd step: Check again 70Nm {7.1kgm} Tighten in
head mounting bolts
order shown
2 (coat bolt seat and thread 3rd step (long mounting bolts only) 145Nm {14.8kgm} in diagram on
with molybdenum disul-
4th step (long m ounting bolts only) C heck left
phide (LM-P)) 145Nm {14.8kgm}
again
5th step Tighten 90
Tightening torque of nozzle

3 24Nm {2.4kgm}
holder
Tighten
Tightening torque of head
4 24Nm {2.4kgm}
cover mounting bolt
114 SERIES 11-17

STRUCTURE AND FUNCTION CYLINDER BLOCK
CYLINDER BLOCK
SAA6D114E-2
1 Main bearing cap

Main bearing cap bolt
a. Center of crankshaft
2
Cylinder block
b. Rear face of cylinder block
3
Cam bushing (journal No. 1)
c. Piston cooling nozzle
4 d. Thrust surface (top surface only, No. 4 journal)
11-18 114 SERIES

Specifications
Cylinder block Piston cooling
Crankshaft: 7 bearings With nozzle piston cooling
Cam shaft: 7 bearings
Cylinder liner ring
Cylinder liner O-ring (x1)
Wet type
Machining of inside surface: Honing
114 SERIES 11-19

CYLINDER BLOCK
11-20 114 SERIES

Unit:mm
Distortion of cylinder head Vertical direction 0.075 Correct by

1
mounting surface Lateral direction 0.075 grinding
Inside diam eter of m ain bear-

Correct or
ing installation
2 Standard size 104.982~105.018 replace cylin-
(Tighten m ounting bolt to
der block
176 Nm (17.9 kgm ))
Inside diameter of main

3a bearing (Tighten bolt to 176 98.079~98.125 Replace
Nm (17.9 kgm)) main bearing
3b Thickness of main bearing 3.340~3.345
Correct or
Inside diameter of cam
4 Max. 64.01 replace cylin-
bushing mounting hole
der block
Inside diameter of cam Replace

5 60.058~60.112
bushing bushing

Tightening torque of main
1st step 50Nm {5.1kgm}
bearing cap mounting bolt
6
(coat bolt thread and seat
2nd step 95Nm {9.7kgm}
with engine oil)
3rd step Tighten 60 5
Tighten
Tightening torque of oil pan

7 24Nm {2.45kgm}
mounting bolt
Tightening torque of crank-

8 shaft pulley pan mounting 200Nm {20.4kgm}
bolt
114 SERIES 11-21

STRUCTURE AND FUNCTION CYLINDER LINER
CYLINDER LINER
Unit:mm
Inside diameter 114.0000~114.040 Correct to

oversize,
Roundness of inside
0.01 install cylin-
1 diameter
der liner, or
Cylindricity of inside replace cylin-
0.01
diameter der block
11-22 114 SERIES

STRUCTURE AND FUNCTION MAIN CIRCULATION PART
MAIN CIRCULATION PART
SAA6D114E-2
The shape may differ according to the machine it is
mounted on.
The numbers in ( ) are used for reference when show-
ing the same part in other places or when explaining
about the same part seen from a different angle.
1. Crankshaft pulley 12. Piston pin a. Ring carrier

2. Crankshaft 13. Top ring b. Toroidal
3. Pin 14. Second ring
4. Crankshaft gear (No. of 15. Oil ring
teeth: 42) 16. Connecting rod cap bolt
5. Main bearing 17. Connecting rod cap
6. Connecting rod bearing 18. Connecting rod cap nut
7. Connecting rod 19. Main bearing
8. Cylinder block 20. Thrust bearing (top sur-
9. Cylinder liner face only, No. 4 journal)
10. Piston 21. Main cap bolt
11. Connecting rod bushing
11-24 114 SERIES

Specifications Piston ring

Crankshaft
Closed die forging, induction hardening Top ring Second ring Oil ring
Piston
Toroidal combustion chamber for direct injection
type
Aluminum piston
Barrel face key- Rectangular inner With coil expander,

stone inner cut, cut, barrel face key- M-shape steel ring,
hard chrome plat- stone inner cut, hard chrome plat-
ing parkerizing ing
114 SERIES 11-25

CRANKSHAFT AND MAIN BEARING
The crankshaft is a balance type forged steel prod-

uct. 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 cen-
ter 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 3-
ring group. The engine with turbocharger and after-
cooler 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 after-

cooler 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 3-
layer bearing can be used for service.
114 SERIES 11-27

STRUCTURE AND FUNCTION CRANK SHAFT
CRANK SHAFT
11-28 114 SERIES

STRUCTURE AND FUNCTION CRANK SHAFT
Unit:mm
Replace
thrust bear-
1 End play (A) 0.085~0.385
ing or correct
oversize
Outside diameter of main Correct

Min. 97.962
journal undersize or
2 Roundness of main journal 0.050 replace
Replace
Clearance of main journal 0.061~0.139
main bearing
Outside diameter of crank- Correct

Min. 75.962
shaft pin journal undersize or
Roundness of pin journal Repair limit: 0.050 replace

3
Replace con-
Clearance of crankshaft pin
0.033~0.117 necting rod
journal
bearing
Correct
4 Curvature of crankshaft Repair limit: Max. 0.15 (total movement of indicator) undersize or
replace
Width of crankshaft thrust

5 42.975~43.070
face
Oil seal wear group at front

6 Max. 0.25
and rear of crankshaft
Replace
Outside diameter of crank-
6 129.975~130.025
shaft rear oil seal flange
Outside diameter of cam-

23.924~24.000
shaft damper pilot
114 SERIES 11-29

STRUCTURE AND FUNCTION PISTON PISTON RING PISTON PIN
PISTON PISTON RING PISTON PIN
11-30 114 SERIES

STRUCTURE AND FUNCTION PISTON PISTON RING PISTON PIN
Unit:mm
Outside diameter of piston skirt Replace

1 113.814~113.886
(at right angle to boss) piston
Top ring 0.35~0.60

Clearance of end gap of piston
2 Second ring 0.35~0.65
ring
Oil ring 0.30~0.60 Replace
piston ring or
Piston ring groove Top ring 1456'~ 1520' piston
3 (keystone angle) Second ring 1436'~ 1500'
Side clearance of piston ring Oil ring 0.020~0.130
4 Outside diameter of piston pin 44.993~45.003 Replace
Outside diameter of piston pin piston or

5 45.006~45.025 piston pin
bore
114 SERIES 11-31

STRUCTURE AND FUNCTION CONNECTING ROD
CONNECTING ROD
11-32 114 SERIES

STRUCTURE AND FUNCTION CONNECTING ROD
Unit:mm
Replace
Inside diameter of connect- bushing
1 ing rod bushing 45.023~45.060 (supply part
(when installing bushing) is semi-fin-
ished part)
Inside diameter of connect- Replace

2 ing rod bushing mounting 48.988~49.012 connecting
hole rod
Inside diameter of connect-

3 76.046~76.104 Replace
ing rod bearing
connecting
Thickness of connecting rod rod bearing
4 2.43~2.471
bearing
Inside diameter of connect-

5 ing rod bearing mounting 80.987~81.013
hole
Curvature Without bushing: 0.20 Replace

With bushing: 0.15 connecting
Curvature, twisting of Twisting Without bushing: 0.50 rod

6
connecting rod b With bushing: 0.30
Dimen-
215.975~216.025
sion c
Tightening torque of con- Step Tightening torque

necting rod cap mounting 1st step 30Nm {3.06 kgm}
7 bolt Tighten
(Coat thread portion of bolt 2nd step 70Nm {7.1 kgm}
and nut with engine oil.) 3rd step Tighten 60 5
Replace
Side clearance of connect-
8 0.100~0.300 connecting
ing rod
rod
114 SERIES 11-33

STRUCTURE AND FUNCTION VIBRATION DAMPER
VIBRATION DAMPER
Unit:mm
1 Lost rubber material 3.18
Inside/ outside misalign-

1.59 Replace
2 ment of damper (A)
Face runout of damper (B)
Tightening torque of vibra-

3 200Nm {20.4 kgm} Tighten
tion damper
11-34 114 SERIES

STRUCTURE AND FUNCTION TIMING GEAR PORTION
TIMING GEAR PORTION
Without front PTO (helical gear)

SAA6D114E-2
1. Oil pump drive gear (No. of teeth: 24)

2. Idler gear (No. of teeth: 23)
3. Crankshaft gear (No. of teeth: 42)
4. Cam gear (No. of teeth: 84)
5. Fuel injection pump drive gear (No. of teeth: 84)
6. Timing pin
11-36 114 SERIES

STRUCTURE AND FUNCTION FRONT GEAR COVER
FRONT GEAR COVER
SAA6D114E-2
1. Front gear cover Specifications

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

STRUCTURE AND FUNCTION CAMSHAFT TIMING PIN
CAMSHAFT TIMING PIN

The shape may differ according to the
machine it is mounted on.
SAA6D114E-2 @
1. Timing housing
2. Timing pin
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

STRUCTURE AND FUNCTION TIMING GEAR
TIMING GEAR
Unit:mm
A Backlash of oil pump gear 0.08~0.33
B Backlash of camshaft gear 0.075~0.325
_ Backlash of each gear C Backlash of oil pump gear 0.08~0.33 Replace
Backlash of fuel injection

D 0.075~0.0325
pump gear
114 SERIES 11-39

STRUCTURE AND FUNCTION CAM SHAFT
CAM SHAFT
11-40 114 SERIES

STRUCTURE AND FUNCTION CAM SHAFT
Unit:mm
Replace
1 End play 0.10~0.36
thrust plate
Outside diameter of cam- Correct or

2 59.987~60.013
shaft bearing journal replace
3 Curvature of camshaft 0.15 (total movement of indicator)
Intake Min. 51.774
Exhaust Min. 51.596 Replace

4 Height of camshaft
Fuel feed
Min. 41.31
pump
Valve
Crank angle
position
Check for
Before top wear,
Intake open 10
dead center
curvature of
5 Valve timing After bottom push rod,
Intake close 34
dead center
camshaft,
Exhaust Before bottom valve, correct
45
open dead center
or replace
Exhaust After top dead
10
close center

6 41.562~41.580
shaft gear mounting face

7 45.550~45.750
shaft thrust bearing journal
Replace
Thickness of camshaft thrust
8 9.34~9.58
plate
Inside diameter of camshaft

9 41.480~41.505
gear bore
ightening torque of camshaft

10 24Nm {2.45kgm} Tighten
thrust plate mounting bolt
114 SERIES 11-41

STRUCTURE AND FUNCTION VALVE MECHANISM
VALVE MECHANISM
SAA6D114E-2
1. Cam bushing (No. 1 journal) 9. Valve spring

2. Cam gear (No. of teeth: 84) 10. Valve cotter
3. Thrust plate 11. Spring seal
4. Camshaft 12. Adjustment screw
5. Exhaust valve 13. Locknut
6. Intake valve 14. Rocker arm
7. Rocker arm bracket 15. Push rod
8. Valve seat (intake, exhaust) 16. Tappet
11-42 114 SERIES

Valve timing
Valve lift Valve opening, closing angle

SAA6D114E-2 SAA6D114E-2
Intake 9.9 mm 10
Intake
Exhaust 11.7 mm 34
45
Exhaust
10
114 SERIES 11-43

CAMSHAFT, TAPPET, PUSH ROD
The camshaft is driven by a gear from the crank-

shaft. 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 main-
tenance bushing is installed, these bores can be cor-
rected 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

STRUCTURE AND FUNCTION VALVE, VALVE GUIDE
VALVE, VALVE GUIDE
11-46 114 SERIES

STRUCTURE AND FUNCTION VALVE, VALVE GUIDE
Unit:mm
Intake 0.59~1.12
Sinking of valve inside Replace valve
1
cylinder head (A) or valve seat
Exhaust 1.09~1.62
Intake Max. 3.01

Thickness of valve head
2 Replace
portion (B)
Exhaust Min. 2.22
Intake 30 Repair limit Correct or

3 Angle of valve seat replace valve,
Use vacuum test to judge condition
Exhaust 45 valve seat
of contact surface
Outside diameter of valve

4 9.49
stem Replace
Diameter of valve guide bore 9.539~9.559
Replace one
4 Clearance between valve or both of
0.039~0.079
guide and valve stem valve and
valve guide
Installed
Standard load Repair limit (N {kg})
Installed load of valve spring length
(intake and exhaust)
5 35.89 960~1060 {98~108} Replace
Right angledness of valve

Max. 1.0
spring
Intake 20.65~21.16
Knocking height of valve
6 Correct
guide
Exhaust 22.55~23.01
Depth of valve insert bore Intake Max. 12.20

7
(standard insert) Exhaust Max. 9.83
Replace
Inside diameter of valve Intake Max. 53.93
8
insert bore (standard insert) Exhaust Max. 47.03
114 SERIES 11-47

STRUCTURE AND FUNCTION ROCKER-ARM SHAFT PUSH ROD TAPPET
ROCKER-ARM SHAFT PUSH ROD TAPPET
11-48 114 SERIES

STRUCTURE AND FUNCTION ROCKER-ARM SHAFT PUSH ROD TAPPET
Unit:mm
Outside diameter of rocker arm Replace rocker

1a 22.199~22.231
shaft arm shaft
Inside diameter of rocker arm Replace rocker

1b 22.256~22.301
shaft hole arm
Clearance between rocker arm Replace rocker

1c 0.025~0.102
shaft and rocker arm arm or shaft
Replace push
2 Curvature of push rod Repair limit: 0.50 (total movement of indicator)
rod
Tightening torque of rocker arm

adjustment screw locknut
Intake side 0.30

4 Valve clearance (when cold) Adjust
Exhaust side 0.56
5a Outside diameter of tappet 15.925~15.980 Replace tappet
Replace cylin-
5b Inside diameter of tappet hole 16.000~16.055
der block
Clearance between tappet and Replace tappet

5c 0.02~0.13
tappet hole or cylinder block
Tightening torque of rocker arm

mounting bolt
114 SERIES 11-49

STRUCTURE AND FUNCTION OIL PAN
OIL PAN
FRONT SUMP TYPE
SAA6D114E-2 (PC300-7)
is mounted on.
1. Oil level gauge

2. Underplate
3. Oil pan
4. Oil level sensor
5. Drain valve
11-50 114 SERIES

1
STRUCTURE AND FUNCTION FLYWHEEL, FLYWHEEL HOUSING
FLYWHEEL, FLYWHEEL HOUSING
SAA6D114E-2
1. Flywheel housing 5. Rear seal

2. Starting motor 6. Rear seal housing
3. Ring gear (No. of teeth: 148) (PC300-7, CD110R-2) 7. Seal ring
(No. of teeth: 127) (WA380-5) 8. Speed sensor (PC300-7, WA380-5, CD110R-2)
4. Flywheel
11-52 114 SERIES

(3)
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
1 Face runout of flywheel housing 0.20

Reassemble,
Radial runout of flywheel hous- correct
2 0.20
ing
Tightening torque of flywheel

housing mounting bolt
For clutch 0.013/24.5

4 Face runout of flywheel Reassemble,
For torque
Diameter at measured point x 0.0005
converter correct
5 Radial runout of flywheel 0.13
Tightening torque of flywheel

6 mounting bolt (Coat bolt thread 137Nm {14.0 kgm} Tighten
portion with engine oil.)
Inside diameter of flywheel 409.58 (WA380-5)

7 _
housing 511.18 (PC300-7, CD110R-2)
114 SERIES 11-55

(3)
STRUCTURE AND FUNCTION LUBRICATION SYSTEM DIAGRAM
LUBRICATION SYSTEM DIAGRAM
SAA6D114E-2
1. Oil strainer 7. Safety valve 13. Timing gear

2. Oil pump (oil filter bypass valve) 14. Fuel injection pump
3. Oil cooler 8. Crankshaft 15. Turbocharger
4. Safety valve 9. Camshaft 16. Piston cooling
(oil cooler bypass valve) 10. Piston 17. Low-pressure oil pressure
5. Regulator valve 11. Intake/exhaust valve switch
6. Oil filter 12. Rocker arm 18. High-pressure oil pressure
switch
11-56 114 SERIES

STRUCTURE AND FUNCTION OIL PUMP
OIL PUMP
SAA6D114E-2
1. Drive gear (No. of teeth: 24) Specifications

2. Bushing Type: Trochoid pump
3. Drive shaft Rotating speed: Engine speed x 1.75
4. Housing
5. Idler shaft
6. Idler gear (No. of teeth: 23)
7. Back plate
8. Inner rotor (drive rotor)
9. Outer rotor (planetary rotor)
114 SERIES 11-57

STRUCTURE AND FUNCTION OIL PUMP
OIL PUMP
Unit:mm
Clearance of rotor in axial

1 0.025~0.127
direction
Clearance between outer rotor Replace oil

2 0.127~0.381
and body pump
Clearance between outer rotor

3 0.025~0.1778
and inner rotor

Tightening torque of oil pump
4 1st step 5Nm {0.5 kgm} Tighten
mounting bolt
2nd step 24Nm {2.4 kgm}
11-58 114 SERIES

STRUCTURE AND FUNCTION OIL FILTER, OIL COOLER
OIL FILTER, OIL COOLER
SAA6D114E-2
1. Oil filter cartridge Specifications

2. Regulator valve Oil cooler
3. Adapter No. of element stages: 12
4. Oil filter head
5. Oil cooler core assembly
6. Oil pump
7. Safety valve
11-60 114 SERIES

STRUCTURE AND FUNCTION REGULATOR VALVE, SAFETY VALVE
REGULATOR VALVE, SAFETY VALVE
SAA6D114E-2
Regulator valve Specifications

1. Plug Regulator valve
2. Spring Cracking pressure: 517 KPa{5.3kg/cm2}
3. Plunger valve
Safety valve
Safety valve Cracking pressure: 345 KPa{3.5kg/cm2}
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
114 SERIES 11-61

(6)
STRUCTURE AND FUNCTION FUEL SYSTEM DIAGRAM
FUEL SYSTEM DIAGRAM
1. Fuel tank 5. Fuel injection pump

2. Priming pump 6. Fuel injection nozzle
3. Feed pump 7. Overflow valve
4. Fuel filter
11-62 114 SERIES

STRUCTURE AND FUNCTION FUEL INJECTION PUMP
FUEL INJECTION PUMP
1. Fuel injection pump (main body) 8. Boost compensator

2. Fuel injection pipe (No. 1) 9. Governor
3. Fuel injection pipe (No. 2) 10. Boost compensator tube
4. Fuel injection pipe (No. 3) 11. Fuel filter
5. Fuel injection pipe (No. 4) 12. Feed pump
6. Fuel injection pipe (No. 5) 13. Timing lock
7. Fuel injection pipe (No. 6) 14. Overflow valve
11-64 114 SERIES

A. Fuel inlet Specifications

B. To fuel filter Fuel injection pump
C. To fuel filter Type: Bosch P3000
D. From fuel filter Lubrication method: Forced lubrication using
E. To fuel injection nozzle engine oil
F. To fuel tank (overflow)
G. From oil pump (oil supply) Governor
Type: Bosch RSV
Centrifugal all-speed type
114 SERIES 11-65

FUEL INJECTION PUMP
Unit:mm
Standard size Tolerance Repair limit

1 Outside diameter of plunger Replace plunger
assembly
2 Function of plunger Generated pressure standard
Correct or
3 Function of delivery valveC Time taken for pressure to drop Standard:
replace
Standard clearance Clearance limit

Replace of
4 learance at top of plunger Cam lift plunger guide
mm hour
Sliding resistance of control

Repair limit Correct
rack
Standard size Repair limit

Free length of plunger spring
5
Installed length Standard load Load limit
Installed load of plunger spring
Replace
Free length of delivery valve Standard size Repair limit
spring
6
Installed load of delivery valve Installed length Standard load Load limit
spring
Tightening torque of delivery

7
valve holder
Tighten
Tightening torque of fuel injec-
44Nm {4.5kgm}
tion pump mounting bolt
11-66 114 SERIES

STRUCTURE AND FUNCTION TIMING LOCK PIN OF FUEL INJECTION PUMP
TIMING LOCK PIN OF FUEL INJECTION PUMP

The shape may differ according to the
machine it is mounted on.
1. Timing lock pin locked
When checking the injection timing of the No 1
cylinder, install lock pin (1-1) in the reverse direc-
tion from the operating condition.
2. Timing lock pin released

The condition of lock pin (1-2) shows the condi-
tion when operating.
(2) shows the damper proof hold.
11-68 114 SERIES

STRUCTURE AND FUNCTION FUEL FILTER
FUEL FILTER
1. Bracket (filter head) Specification

2. Connector Fuel filter
3. Cartridge Filtering area: 0.4 m2
A. Fuel inlet port

B. Fuel outlet port
114 SERIES 11-69

STRUCTURE AND FUNCTION FUEL INJECTION NOZZLE
FUEL INJECTION NOZZLE
1. Gasket A. Fuel inlet port (from injection pump)

2. Retaining cap B. Fuel outlet port (inside fuel chamber)
3. Nozzle body C. Fuel return port (to fuel tank)
4. Needle valve
5. Disc Specifications
6. Injector Type: Bosch multi-hole type, cylindrical type
7. Injector seal Injection pressure (adjusting cracking pressure)
8. Shim (for adjusting cracking pressure) 30MPa {306kg/cm2}
9. Spring Adjusting cracking pressure: Shim adjustment
10. Push rod
11-70 114 SERIES

STRUCTURE AND FUNCTION FUEL INJECTION NOZZLE
FUEL INJECTION NOZZLE
Unit:mm
Spray angle Replace nozzle
Standard Repair limit

1 Nozzle cracking pressure Adjust or
(injection pressure) 29.4~30.4 MPa replace
{300~310 kg/cm2}
Standard size Repair limit

Free length of nozzle spring
2 Replace
Installed length Standard load Load limit
Installed load of nozzle spring
114 SERIES 11-71

STRUCTURE AND FUNCTION FUEL CUT SOLENOID
FUEL CUT SOLENOID
1. Connector Specifications
2. Solenoid case Type : Synchrostart
3. Rod end B contact : Electricity flows in ordinary
operations type.
When the engine is started, electricity flows Rated voltage : DC24V
through the solenoid, so the solenoid plunger is : At suction 29.3A
actuated to extend the return spring (built into Actuating current : At hold: 0.58A
the solenoid) and hold it pulled to the engine Suction force : 89N {9.1 kg}
RUN position. Stroke : 25.4 mm
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.
11-72 114 SERIES

1
STRUCTURE AND FUNCTION COOLING SYSTEM DIAGRAM
COOLING SYSTEM DIAGRAM
SAA6D114E-3
1. Radiator 7. Cylinder block

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

STRUCTURE AND FUNCTION WATER PUMP DRIVE
WATER PUMP DRIVE

is mounted on.
The illustration shows the PC300-7.
1. Polyvinyl V-belt A. To radiator

2. Crankshaft pulley B. From radiator
3. Auto tensioner a, b, c, d, e: Outside diameter of pulley
4. Water pump
5. Alternator
6. Idler pulley
11-74 114 SERIES

STRUCTURE AND FUNCTION WATER PUMP DRIVE
OUTSIDE DIAMETER OF PULLEY
(Unit: mm)
Outside diameter of pulley
a (Water pump) b (Alternator) c (Tensioner) d (Idler) e (Crankshaft)
PC300-7
116 80 73 73 198
CD110R-2
WA380-5 116 80 73 73 198
SAA6D114E-2
GD655-3A,3C 116 80 73 180 198
GD675-3A,3C 116 80 73 180 198

D63E-12
SA6D114E-2 116 80 73 73 198
(For Russia)
114 SERIES 11-75

(5)
STRUCTURE AND FUNCTION WATER PUMP
WATER PUMP
(WITH ONE-PIECE BEARING, SHAFT, ONE-PIECE WATER SEAL)
Depending on the machine model, the actual
component may be different from the diagram.
1. Impeller Water pump

2. Water seal Type: Centrifugal, driven by poly vinyl V-belt
3. Pump body
4. Pulley
5. Drive shaft
A. Water inlet port

B. Water outlet port (to engine)
C. Breather (drain hole)
11-76 114 SERIES

STRUCTURE AND FUNCTION THERMOSTAT
THERMOSTAT
Depending on the machine model, the actual compo-

nent may be different from the diagram.
1. Piston
2. Spring
3. Case
4. Bypass spring
5. Bypass valve
114 SERIES 11-77

STRUCTURE AND FUNCTION THERMOSTAT
THERMOSTAT
Unit: mm
Fully open temperature: 95C Fully open: Must open when

soaked in hot water of 95 77C
1 Thermostat Replace
for 4 5 min (soak in hot water of
Fully open lift amount: 11 95C for 4 5 min)
11-78 114 SERIES

(6)
STRUCTURE AND FUNCTION FAN DRIVE
FAN DRIVE
1. Crankshaft pulley A. Direction of air flow

2. Poly v-belt a, b, c: Outside diameter
3. Auto tensioner of pulley pickup port
4. Fan
5. Fan hub
6. Fan bracket
11-80 114 SERIES

STRUCTURE AND FUNCTION FAN DRIVE
OUTSIDE DIAMETER OF PULLEY
(Unit:mm)
Outside diameter of pulley
a (Fan) b (Tensioner) c (Crankshaft)
PC300-7 228 73 170
CD110R-2 228 73 170

SAA6D114E-2
Note: WA380-5, GD655-3A,3C, GD675-3A,3C, D63E-12 (For Russia) has no fan drive.
114 SERIES 11-81

(5)
STRUCTURE AND FUNCTION ALTERNATOR
ALTERNATOR
Alternator with built-in regulator (35A)
1. Alternator (main body) 6. Internal connection diagram

2. Alternator pulley 3A. Field coil
3. Terminal E 3B. Initial magnetize resestor
4. Terminal B 3C. Regulator
5. Terminal R
Pulley
Weight
Engine Machine model Type Specification Outside
No. of steps (kg)
diameter
PC300-7 Nikko Denki, Polyethylene

SAA6D114E-2 24V, 35A 80 8.0
CD110R-2 open type V-belt, 8 grooves
D63E-12 Nikko Denki, Polyethylene

SA6D114E-2 24V, 35A 80 8.0
(For Russia) open type V-belt, 8 grooves
11-82 114 SERIES

(5)

3. Terminal E 6B. Initial magnetize resestor
5. Terminal R
Pulley
Weight
Engine Machine model Type Specification
Outside (kg)
No. of steps
diameter
WA380-5
Nikko Denki, Polyethylene
SAA6D114E-2 GD655-3A,3C 24V, 60A 80 11.0
open type V-belt, 8 grooves
GD675-3A,3C
114 SERIES 11-83

(2)
1

3. Terminal R 6B. Initial magnetize resestor
5. Terminal E
Pulley
Weight
Engine Machine model Type Specification
Outside (kg)
No. of steps
diameter
GD655-3A,3C Nikko Denki, Polyethylene

SAA6D114E-2 24V, 90A 80 19.0
GD675-3A,3C open type V-belt, 8 grooves
11-84 114 SERIES

(1
2)
STRUCTURE AND FUNCTION STARTING MOTOR
STARTING MOTOR
7.5KW

1. Pinion gear 7. External connecting diagram

2. Magnetic switch 7A. Safety relay
3. Starting motor (yoke) 7B. Starting motor
4. Terminal B 8. Connector type
5. Terminal C A type: 2P connector (male)
6. Air hole for water proof test B type: 2P sealed type connector (male)
S to starter switch terminal C
R to Alternator terminal R
No. of pinion Connector

Engine Machine model Type Specification Weight (kg)
teeth type
PC300-7
WA380-5
SAA6D114E-2 GD655-3A,3C Nikko Denki, sealed type 24V, 7.5kW 12 15.5 B
GD675-3A,3C
CD110R-2
114 SERIES 11-85

(3)
11KW
1. Pinion gear 7A. Safety relay

2. Starting motor (Assembly) 7B. Starting motor
3. Magnetic switch A type: 2P connector (male)
4. Terminal B B type: 2P sealed type connector (male)
5. Terminal C S to starter switch terminal C
6. Safety relay R to Alternator terminal R
7. External connecting diagram E to ground
No. of pinion Connector

Engine Machine model Type Specification Weight (kg)
teeth type
GD655-3A,3C
SAA6D114E-2 Nikko Denki, sealed type 24V, 11kW 12 18.0 B
GD675-3A,3C
D63E-12
SA6D114E-2 Nikko Denki, sealed type 24V, 11kW 12 18.0 B
(For Russia)
11-86 114 SERIES

(5)
STRUCTURE AND FUNCTION STARTING AID
STARTING AID
ELECTRICAL HEATER (ELECTRICAL INTAKE AIR HEATER)
Depending on the machine model, the actual component may

be different from the diagram.
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

(6)
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 sealin performance ................................................................................................... 12-32
Valve seal wear ............................................................................................................................. 12-33
Protruding portion of fuel injection nozzle ..................................................................................... 12-34
114 SERIES 12-1

Front 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
Flywheel 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
Fuel in oil ....................................................................................................................................... 12-49
FUEL
Fuel 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 FOR TESTING, ADJUSTING, AND TROUBLESHOOTING .................... 12-200
TROUBLESHOOTING OF ENGINE (S MODE) ...................................................................................... 12-301
114 SERIES 12-3

TESTING AND ADJUSTING SPECIAL TOOL LIST
SPECIAL TOOL LIST

SPECIAL TOOLS FOR 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. Explanation of tool Sketch of tool

Depth gauge
This is used to measure the movement of the turbo-
charger in the axial direction.
795-790-1800
Pressure gauge
This is used to measure the intake manifold pressure
and the exhaust return pressure.
795-790-1470
Pressure test kit

This is used to measure the exhaust pressure.
795-790-1700
12-4 114 SERIES

SPECIAL TOOLS FOR CYLINDER HEAD SYSTEM

The tools shown below are used when carrying out inspection of the cylinder head. For details of the method of
using the tools, see the applicable operation procedure.

Valve spring compression tool
This is used to compress the valve spring when remov-
ing the valve cotter.
ST-488
Cylinder head holding tool

This is used to hold the cylinder head when rotating it
during repair or assembly.
ST-583
Valve seat grinder

This is used to grind the valve seat inside the cylinder
head. Choose the suitable grindstone from the tool list
ST-685
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
15. (Diameter 47.6 mm)
ST-6835-13
Magnetic particle flaw detector

This is used to inspect the inside diameter of the injec-
tor at the cylinder head combustion surface and cracks
ST-1166
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
the tester is used. This is used to carry out a vacuum
ST-1257
test on the cylinder head to check if the valve seat sur-
face is normal.
114 SERIES 12-5


Valve seat puller tool
This is used when removing the exhaust valve seat from
the cylinder head. It is used together with a slide ham-
ST-1276-1
mer (Part No. 3376617).
Valve spring tester

This is used to measure the tension of the cylinder head
valve spring.
3375182
Light-load power-drive puller

This is used when removing the expansion plug from
the cylinder head.
3375784
Valve chamfering machine

This is used to grind the cylinder head valve and to cor-
rect the valve stem surface.
3376256
Valve seat groove cutting kit

This is used together with the cutter (Part No. 3376407)
of the valve seat puller tool (Part No. ST-1276 and Part
3376405
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
No. ST-1276 and Part No. 337-7396) in order to remove
3376617
the valve seat from the cylinder head.
Expansion plug driver

This is used when installing the 3/4 inch expansion plug
to the determined depth.
3376815
12-6 114 SERIES


Valve seat puller tool
This is used when removing the intake valve seat from
the cylinder head. It is used together with a slide ham-
3377396
mer (Part No. 3376617).
Valve guide reamer

This is used to enlarge the valve guide hole to a suitable
inside diameter after assembly.
3822490
Injector hole brush

This is used to remove all the carbon from the injector
hole.
3822510
Valve seat grindstones

3823179 Used to grind intake valve seat angle to 5
(diameter: 57.2 mm)
(diameter: 53.9 mm)
(diameter: 47.6 mm)
3823184 Used to grind exhaust valve seat angle to 60

(diameter: 44.4 mm)
(diameter: 50.8 mm)
Valve seat grinding arbor

This is used together with Part No. ST-685, the valve
seat grinder, and various grindstones to maintain a suit-
3823187
able alignment during the grinding operation.
3823272 Valve guide drive circuit

3823269 This is used to install the intake valve guide.
3823270 This is used to install the exhaust valve guide.
3823271 This is used to remove the intake and exhaust valve
guides.
114 SERIES 12-7


Gauge block
This is used to measure the sinking of the valve and the
protrusion of the injector from the top surface of the cyl-
3823495
inder head.

This is used to install the 13/16 inch expansion plug to
the specified depth.
3823522

This is used to install the 2-1/4 inch expansion plug to
the specified depth.
3823524
Bolt length gauge

This is used to check the free length of the cylinder
head mounting bolt.
3823921
12-8 114 SERIES

SPECIAL TOOLS FOR ENGINE

We recommend the use of the tools shown below when carrying out inspection of the engine. For details of the
method of using the tools, see the applicable operation procedure.

Connecting rod inspection holder
This is used to measure the length, sag, and alignment
of the inside diameter of the connecting rod. It is used
ST-561
together with the connecting rod inspection mandrel kit
(Part No. 3823286).
Dowel pin puller

This is used to remove the dowel pin.
ST-1134
Expansion plug sealant

This is used to prevent leakage when installing tapered
thread plugs or cup plugs to the engine.
3375068
Dial bore gauge kit

This is used to measure the inside diameter from 78.5
to 203.2 mm.
3375072
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


Nylon sling
This is used when removing or installing the crankshaft,
flywheel, or other heavy components.
3375957
Handle for expansion plug drive

This is used for all large expansion plugs with a diame-
ter of 9.5 mm or more.
3376795

This is used to install the 25.4 mm expansion plug to the
specified depth. It is used together with the handle of
3376816
the expansion plug driver (Part No. 3376795).

specified depth.
3822372
Metric thread insertion kit

This is used to repair the damaged internal metric
thread.
3822709
Piston ring expansion

This is used to install the piston ring to the piston with-
out damaging or deforming the ring.
3823137
Connecting rod mandrel kit

This is used to measure the length, sag, and alignment
of the inside diameter of the connecting rod. It is used
3823286
together with the connecting rod inspection inspection
holder (Part No. ST-561).
12-10 114 SERIES


Camshaft bushing removal/installation tool
This is used to remove or install the camshaft bushing.
3823509

3823521

3823522

3823523

specified depth.
3823524
Connecting rod pin bushing removal/installation

tool
This is used to remove or install the service bushing at
3823690
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


Wear gauge for piston ring groove (keystone)
This is used to measure the wear of the keystone angle
of the middle piston ring groove.
3823965
Wear gauge for piston ring groove (keystone)

This is used to measure the wear of the keystone angle
of the top piston ring groove.
3823966
12-12 114 SERIES

SPECIAL TOOLS FOR FUEL SYSTEM

We recommend the use of the tools shown below when carrying out inspection of the fuel system. For details
of the method of using the tools, see the applicable operation procedure.

Brush
This is used to clean the fuel injection nozzle bore.
795-799-1140
Injector nozzle tester

This is used to test the cracking pressure, leakage,
chattering, and spray pattern.
3376946
Nozzle cleaning kit

This is used to clean the injection nozzle.
3376947
114 SERIES 12-13

SPECIAL TOOLS FOR ACCESSORY COMPONENT SYSTEM

We recommend the use of the tools shown below when carrying out inspection of the accessory component
system. For details of the method of using the tools, see the applicable operation procedure.

Oil filter wrench
This is used to remove or install the oil filter.
3375049
Valve spring tester

This is used to measure the spring force at the specified
height.
3375182
Tube cutter
This is used to open the full-flow oil filter when inspect-
ing the filter element.
3376579
Oil cooler pressure test kit

This is used to test the pressure of the oil cooler ele-
ment.
3823876
Dial gauge and sleeve assembly

This is used together with the magnet base (Part No.
3377399) to measure the clearance from the fan hub.
3376050
Magnet base dial gauge holder

This is used together with the dial gauge and sleeve
assembly (Part No. 3376050).
3377399
Standard puller
This is used to replace the drive gear.
ST-647
12-14 114 SERIES

SPECIAL TOOLS FOR ELECTRICAL COMPONENT

We recommend the use of the tools shown below when carrying out inspection of the electrical component. For
details of the method of using the tools, see the applicable operation procedure.

Multimeter
This is used to measure the voltage in the circuit and
Commercially resistance.
available
114 SERIES 12-15

SPECIAL TOOLS FOR ENGINE PERFORMANCE TEST


Vacuum gauge
This is used to test the resistance of the fuel filter during
the engine performance test. Use Part No. ST-434-2
795-790-1500
(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
intake manifold.
795-790-1470
Wrench
This is used to remove or tighten the spin-on lubricating
oil filter or fuel filter.
795-799-1320
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
measure the pressure in the engine crankcase.
795-790-1610
Portable pressure kit

This is used to measure the lubricating oil pressure.
795-790-1100
12-16 114 SERIES


Tachometer
This is used to measure the engine speed (rpm).
799-203-8001
114 SERIES 12-17

TROUBLESHOOTING DEFECTIVE ACTUATION
TESTING AND ADJUSTING OF INTAKE AND EXHAUST SYSTEM
TROUBLESHOOTING DEFEC-
TIVE ACTUATION OF 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 sys-
tems, 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 tur-
bocharger 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 exces-

sive 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 resis-
tance 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 mainte-
nance 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 natu-
rally aspirated engines, measure the resistance just
before the intake manifold.
12-18 114 SERIES

DAMAGE CAUSED BY UNFILTERED

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 mani-
fold, 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 dam-

aged, and will lead to loss or balance of the wheel
and damage to the bearings.
To check if the bearings have failed or the compres-
sor 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 OF SUPPLIED AIR

(ENGINES WITH THE TURBO-
CHARGER)
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. Expla-
nation will be given of the manifold pressure later.
LEAKAGE OF 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 rota-
tion 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 exces-
sive exhaust smoke, drop in the manifold pressure,
and drop in the output.
MEASURING PRESSURE OF TURBO-

CHARGER AIR (ENGINE WITH TUR-
BOCHARGER)
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 resis-
tance of the turbocharger boost pressure to
check the condition. For 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

DEFECTIVE ACTUATION OF TURBO-

CHARGER (ENGINE WITH TURBO-
CHARGER)
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 operat-
ing pressure of the engine. The oil is drained to the
oil pan through the return line connected to the bot-
tom of the turbocharger.
Seal rings are used at both ends of the rotor assem-

bly, 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 possi-
ble failure.
Caution: If the pressure in the crankcase is exces-
sively high, the oil will not drain from the tur-
bocharger. 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 cas-
ing and crossover tube. As explained above, check
the resistance and remove the cause.
NOISE FROM 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 DEFECTIVE ACTUATION OF INTAKE AND EXHAUST SYSTEM
TESTING AND ADJUSTING MEASURING PLAY OF TURBOCHARGER ROTOR IN AXIAL AND RADIAL DIRECTION
Before removing the turbocharger, check if the noise

is caused by leakage from the intake or exhaust pis-
ton.
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 parti-
cles of dirt inside the system or the rotor assembly is
contacting the housing.
MEASURING PLAY OF TUR-

BOCHARGER ROTOR IN
AXIAL AND RADIAL DIREC-
TION (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 0.03 mm
Max 0.08 mm
114 SERIES 12-23

MEASURING PLAY OF TURBOCHARGER ROTOR IN AXIAL AND RADIAL DIRECTION
TESTING AND ADJUSTING TESTING TURBOCHARGER WESTGATE VALVE
Measuring clearance in radial direction of shaft
Clearance in radial direction (B)

Min 0.21 mm
Max 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. For details of the
procedure for reassembly.
Check if the valve and valve seat are cracked or cor-

roded.
If the wear of the turbine housing assembly is exces-
sive, replace the assembly. For details of the proce-
dure for reassembly.
Move the lever by hand and check that shaft rotates

freely without catching. Check that there is no exces-
sive 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 AND ADJUSTING TESTING ACTUATION OF 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 OF
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 OF TURBOCHARGER WESTGATE
TESTING AND ADJUSTING 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 suffi-
cient 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

TESTING AND ADJUSTING 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 actu-

ator.
Install the tip of the adjustment link to the new actua-

tor 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

TESTING AND ADJUSTING ADJUSTING TURBOCHARGER WESTGATE ACTUATOR
ADJUSTING TURBO-
CHARGER WESTGATE ACTU-
ATOR (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 Pressure
All 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 align-
ment of the clevis pin.
If necessary, adjust the westgate to set to the speci-
fied 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
TESTING AND ADJUSTING 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 assem-
bly.
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 turbo-

charger 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

TESTING AND ADJUSTING TROUBLESHOOTING DEFECTIVE ACTUATION OF ENGINE
TIVE ACTUATION OF 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 FUEL

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 suf-
ficient 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 cor-
rectly, 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

PERFORMANCE
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 compres-
sion will drop.
114 SERIES 12-31

VALVE SEALING PERFORMANCE

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

PERFORMANCE
If the compression of the neighboring cylinder is low
and the pressure does not rise even when oil is sup-
plied 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 cool-
ing 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 sys-
tem 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 OF FUEL

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 sur-

face, use a thicker service head gasket.
After machining, distinguish the cylinder head as fol-

lows.
Machining Mark
A - Standard None
B - Machine 0.25 mm for the 1st oversize
gasket
C - Machine 0.25 mm for the 2nd oversize
gasket [Total: 0.50 mm]
12-34 114 SERIES

When the machining amount has been achieved,

look at the parts catalog and select a suitable over-
size head gasket.
FRONT 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 perfor-
mance.
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. For detailed explanation of the
replacement procedure.
114 SERIES 12-35

ROCKER LEVER, VALVE STEM,

PUSH ROD, TAPPET, AND
CAMSHAFT
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 fil-
ter. 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 vari-
ous problems related to the output, such as exces-
sive 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, rang-

ing 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 cylin-
der 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 out-
put 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 bear-
ing.
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. First, apply load,
then run under no load to check if you can hear any
knocking.
CRANKSHAFT AND MAIN BEARING

Improper maintenance of the lubrication system is a
main cause of reduction in the lift of the main bear-
ing.
Normally, It is possible to recognize defective opera-
tion 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 0.085 mm
Max 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 direc-
tion 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 distin-
guish the problem.
12-40 114 SERIES

FLYWHEEL HOUSING AND

FLYWHEEL
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 con-
centricity of the flywheel housing and flywheel and to
measure the alignment of the flywheel housing rear
face.
114 SERIES 12-41

TESTING AND ADJUSTING ADJUSTING VALVE CLEARANCE
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 com-
pression 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 install-
ing the valves - max. 60C
Caution: When sliding the clearance gauge between
the valve stem and rocker lever, the clear-
ance 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

TESTING AND ADJUSTING TROUBLESHOOTING DEFECTIVE ACTUATION OF LUBRICATING SYSTEM
TIVE ACTUATION OF LUBRI-
CATING SYSTEM
OUTLINE
When carrying out troubleshooting, check the
gauges, high or low level of the oil, excessive con-
sumption 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 start-
ing 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 tempera-
ture. 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 pres-

sure is intermittently lost when traveling around cor-
ners 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 FILTER
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 OF 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. Fuel 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 gas-
ket 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.
FUEL IN OIL
Dilution by fuel is caused by one of the following five
problems.
9. Fuel 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
Drop in Drop in Excessive
white smoke Normal output
output output black smoke
when starting
Test compression and check Check for leakage from fuel

Check, replace injector
ring sealing 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 cylin-

der 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

TESTING AND ADJUSTING FUEL INJECTION PUMP CALIBRATION DATA
FUEL INJECTION PUMP CALIBRATION DATA
Engine model Pump assembly No. Engine serial No. Applicable machine Page
6743-71-1122 WA380-5 12-53
6743-71-1131 PC300-7, CD110R-2 12-54
6743-71-1220 GD655-3 12-55

6742-71-1120 12-56
D68ESS-12E0
SAA6D114E-2
12-52 114 SERIES

(6)
Injection Pump Assembly Number

6743-71-1122 (0 402 066 733 Rev. 2)
( ): Injection Pump Manufacturers part No.
Applicable Machine Applicable Engine
Model Serial No. Model Serial No.
Injection Injection Pump
WA380-5 SAA6D114E-2
Pump Type Manufacturer
P3000 Bosch
Injection Pump Specification Engine Specification

Rotating direction Clockwise Flywheel horsepower (kW {HP}/rpm) 151.5 {203}/2,000 (Gross)
Injection order 153624 Max. torque (Nm {kgm}/rpm) 945 {96.4}/1,400 (Gross)
Injection interval 60 0.75 High idle speed (rpm) 2,250 50
Plunger prestroke (mm) 3.6 0.1 Low idle speed (rpm) 920 + 50
0
Delivery valve
(mm3/st) 120 Test stand capacity Motor: 7.5 kW
retraction volume
Calibration Standard ( ): Injection pump manufacturers part number
Conditions Service standard Manufacturer standard
Service standard Nozzle & Nozzle holder part No. (1 688 901 103)
indicates data Nozzle part No.
using calibration
Nozzle holder part No.
test parts.
Manufacturer Injection pipe (Outside
(mm) 8.0 3.0 600
dia. x Inside dia. x Length)
standard is data
for factory test Test oil ISO 4133
parts. Oil temperature (C) 40 2
Nozzle opening pressure (MPa {kg/cm2}) 20.7 21.0 {211 214}
Transfer pump pressure (kPa {kg/cm2})
Pump part No. 6743-71-1122 (Cum 4063700) Bosch combination No. 0 402 066 733 Rev. 2
Pump spec. No. Cum 4063701
Max. SP.
Bosch Speed L.D.A. Press Fuel Rack
Attribute CYL/CYL
I.D. (prpm) kPa (mmHg) (mm3/st) (mm3/st) (mm)
Rated V1 1000 100 (750) 165.5 3.0 7.5 13.4 0.1
Torque peak V2 750 100 (750) 175.0 6.0 13.4 0.2
No air VS 750 0 121.5 3.0 10.95 0.3
Governor break A1 1055 10 100 (750) 12.4
High idle w/o bumper A2 1130 10 100 (750) 4.0
Governor rack runout A3 1200 100 (750) 0.85 0.55
High idle w/bumper A4 1140 20 100 (750) 4.0
Boost control P1 750 100 (750) 13.4 0.2
Boost control VS & P2 750 0 121.5 3.0 10.95 0.3
Boost control VLDA &P3 750 20.5 (154) 139.0 3.0 11.8 0.3
Boost control P4 750 50 (375) 13.3 0.3
Start fuel St 100 148.0 25.0 20.5 0.5
Low idle w/o bumper LO 475 4.7 0.3
Low idle w/bumper L1 & LQ 475 27.0 4.5 7.5 5.2 0.3
Bench test equipment Supplier PN
Overflow valve ................................................................... 2 417 413 101 Inlet press.: 200 10 (1500 75) kPa (mmHg)
114 SERIES 12-53

(4)

6743-71-1131 (0 402 066 729)
PC300-7 SAA6D114E-2
CD110R-2
P3000 Bosch

Rotating direction Clockwise Flywheel horsepower (kW {HP}/rpm) 190 {254}/1,900 (Gross)
Injection order 153624 Max. torque (Nm {kgm}/rpm) 1,110 {113}/1,400 (Gross)
Plunger prestroke (mm) 3.6 0.1 Low idle speed (rpm) 900 25
Delivery valve
retraction volume
using calibration
test parts.
(mm) 8.0 3.0 600
standard is data
Pump part No. 6743-71-1131 (Cum 4063536) Bosch combination No. 0 402 066 729
Max. SP.
Attribute CYL/CYL
Rated V1 950 110 (825) 187.5 3 7.5 14.8 0.1
Torque peak V2 700 110 (825) 196.0 6 14.8 0.3
No air VS 500 0 75 3 9.8 0.3
Governor break A1 1000 10 110 (825) 13.8
Governor rack runout A3 1140 110 (825) 0.85
Boost control P1 500 110 (825) (14.8)
Boost control VS & P2 500 0 75 3 9.8 0.3
Boost control VLDA &P3 500 25 (188) 11.1 0.3
Boost control P4 500 50 (375) 13.3 0.3
Start fuel St 100 0 104.6 25 9.8 0.5
Low idle w/bumper L1 & LQ 400 0 17.0 4.5 7.5 5.2 0.2
Low idle L3 100 > 19
12-54 114 SERIES

(4)

6743-71-1220 (0 402 066 733AB)
GD655-3 SAA6D114E-2
P3000 Bosch

Rotating direction Clockwise Flywheel horsepower (kW {HP}/rpm) 147 {197}/1,900 (Gross)
Injection order 153624 Max. torque (Nm {kgm}/rpm) 940 {95.7}/1,400 (Gross)
Plunger prestroke (mm) 3.6 0.1 Low idle speed (rpm) 825 50
Delivery valve
retraction volume
using calibration
test parts.
(mm) 8.0 3.0 600
standard is data
Pump part No. 6743-71-1220 (Cum 4063871) Bosch combination No. 0 402 066 733AB
Max. SP.
Attribute CYL/CYL
Rated V1 950 100 (750) 143.5 3.0 7.5 12.35 0.1
Torque peak V2 700 100 (750) 163.5 6.0 13.0 0.2
No air VS 750 0 113.5 3.0 10.6 0.3
Governor break A1 1070 10 100 (750) 12.4
Governor rack runout A3 1250 100 (750) 0.85 0.55
Boost control P1 750 100 (750) 13.0 0.2
Boost control VS & P2 750 0 113.5 3.0 10.60 0.3
Boost control VLDA &P3 750 25 (188) 127.0 3.0 11.2 0.3
Boost control P4 750 62 (465) 12.4 0.3
Start fuel St 100 148.0 25.0 20.5 0.5
Low idle w/bumper L1 & LQ 412 34.5 4.5 7.5 5.9 0.3
114 SERIES 12-55

(4)

6742-71-1120 (101600-3101)
D63E-12 SA6D114E-2
(For Russia)
AD Bosch D68ESS-12E0

Rotating direction Clockwise Flywheel horsepower (kW {HP}/rpm) 126.7 {170}/1,800 (Gross)
Injection order 153624 Max. torque (Nm {kgm}/rpm) 853 {87}/1,400 (Gross)
Injection interval 60q r 0.75q High idle speed (rpm) 2,000 r 50
Plunger prestroke (mm) 3.6 r 0.1 Low idle speed (rpm) 915 r 25
Delivery valve
retraction volume
Service standard Nozzle & Nozzle holder part No. (105780-8140)
indicates data Nozzle part No. 105780-0000
using calibration Nozzle holder part No. 105780-2080
test parts.
Injection pipe (Outside
Manufacturer (mm) 6.00 u 2.0 u 600
standard is data
for factory test Test oil ASTM D975 No.2 diesel fuel or equivalent
parts. Oil temperature (qC) 40
Nozzle opening pressure (MPa {kg/cm2}) 17.2 {175}
Transfer pump pressure (kPa {kg/cm2}) 255 {2.00}
Injection volume Service standard (cc/1,000 st) Manufacturer standard (cc/1,000 st)
Rack
Rack Pump Maximum Maximum
point
position speed variance variance
(mm) (rpm) Injection volume Injection volume
Rack positions between between
cylinder cylinder
B to E are the
reference volume A (Basic point) 10.2 900 154 1 2.5%
when adjusting the B 10.65 650 (179) 2
injection volume. C ~ 6.3 460 12.5 2 15%
Marks a are D Min. 14.5 100 (175)
average volumes.
E
Governor performance curve Boost compensator performance curve
12-56 114 SERIES

(6)
TESTING AND ADJUSTING RUNNING IN STANDARD
RUNNING IN STANDARD
Engine Applicable Order

Item
model machine 1 2 3 4 5 6
Running time min. 2 10 2 3 1,200

PC300-7 Engine speed rpm 900 1,000 1,200 1,600 1,900
CD110R-2 Load N{kg} 0 {0} 98 {10} 245 {25} 637 {65} 1,294 {132}
Flywheel horsepower kW{HP} 0 {0} 7 {10} 22 {30} 76 {103} 185 {247}

Engine speed rpm 920 1,000 1,200 1,600 2,000
WA380-5
Load N{kg} 0 {0} 98 {10} 245 {25} 637 {65} 1,010 {103}
SAA6D114E-2
GD655-3A Engine speed rpm 825 1,000 1,200 1,600 1,900
GD655-3C Load N{kg} 0 {0} 98 {10} 245 {25} 637 {65} 1,030 {105}

GD675-3A Engine speed rpm 825 1,000 1,200 1,600 1,900
GD675-3C Load N{kg} 0 {0} 98 {10} 245 {25} 637 {65} 1,080 {111}
Running time min. 2 10 2 3 10

D63E-12 Engine speed rpm 915 1,000 1,200 1,600 1,800
(For Russia) Load N{kg} 0 {0} 98 {10} 245 {25} 637 {65} 939 {95.8}
Flywheel horsepower kW{HP} 0 {0} 7 {10} 22 {30} 76 {103} 126.7 {170}
SA6D114E-2
D68ESS- Engine speed rpm 825 1,000 1,200 1,600 1,900
12E0 Load N{kg} 0 {0} 98 {10} 245 {25} 637 {65} 1,080 {111}
Running time min.

Engine speed rpm
Load N{kg}
Flywheel horsepower kW{HP}
Running time min.

Engine speed rpm
Load N{kg}
Flywheel horsepower kW{HP}
H This table shows the standard values for the engine without fan.
H The loads for the dynamometer in this table are at an arms length of 716 mm.
114 SERIES 12-101

(6)
TESTING AND ADJUSTING PERFORMANCE TEST CRITERIA
PERFORMANCE TEST CRITERIA

H This table gives the standard values using the JIS correction factor.
H The outputs and torques in this table are the standard values when the fan is removed, so they are differ-
ent from the specification values.
H This table shows the standard for a machine with an air cleaner installed, alternator under no load, and air
compressor (if equipped) open.
H The loads for the dynamometer are at an arm's length of 716 mm.
Engine Applicable Engine Speed Dynamometer

Test item Specifications
model machine (rpm) N{kg}
Flywheel horsepower 180kW/1,900rpm 1,900 5 { }

{242HP/1,900rpm}
(Net)
Max. torque 1,078Nm/1,400rpm 1,400 100
PC300-7 {110kgm/1,400rpm} { }
CD110R-2 (Net)
High idling speed 2,180 50rpm 2,180 50
Low idling speed 900 r 25rpm 900 25

{187HP/2,000rpm}
(Net)
Max. torque 883Nm/1,400rpm 1,400 100
{90kgm/1,400rpm} { }
WA380-5
(Net)
High idling speed 2,250 r 50rpm 2,250 50
Low idling speed 920 + 50rpm 920 + 50

0 0
SAA6D114E-2
{197HP/1,900rpm}
(Gross)
Max. torque 940Nm/1,400rpm 1,400 100
GD655-3A {96kgm/1,400rpm} { }
GD655-3C (Gross)
Low idling speed 825 r 50rpm 825 50

{207HP/1,900rpm}
(Gross)
Max. torque 989Nm/1,400rpm 1,400 100
GD675-3A {101kgm/1,400rpm} { }
GD675-3C (Gross)
Low idling speed 825 50rpm 825 50
Flywheel horsepower 126.76.3kW/1,800rpm 1,800 { }

{1708.5HP/1,800rpm}
(Gross)
D63E-12 Max. torque 85343Nm/1,300rpm 1,300
(For Russia) {874.4kgm/1,300rpm} { }
SA6D114E-2
D68ESS- (Gross)
12E0 High idling speed 2,000 50rpm 2,000 50
Low idling speed 915 50rpm 825 50
12-120 114 SERIES

(6)
TESTING AND ADJUSTING PERFORMANCE TEST CRITERIA
For fuel, use JIS No. 2 diesel oil.

For lubricant, use SAE30 oil.
Flywheel Torque Fuel Cooling water Lubricating oil Lubricating oil Exhaust
horsepower consumption temperature temperature pressure temperature
Nm(kgm)
kW(HP) (sec/100cc) (C) (C) kPa{kg/cm2} (C)
Min. 83 95 80 110 343 588 Max. 550
{ } {3.5 6.0}
(Gross)
343 588
83 95 80 110 Max. 550
{ } {3.5 6.0}
(Gross)
343 588
83 95 80 110
{3.5 6.0}
83 95 80 110 Min. 147
{Min. 1.5}
Min. 83 95 80 110 343 588 Max. 550
{ } {3.5 6.0}
(Gross)
343 588
83 95 80 110 Max. 550
{ } {3.5 6.0}
(Gross)
343 588
83 95 80 110
{3.5 6.0}
83 95 80 110 Min. 147
{Min. 1.5}
Min. 70 90 90 110 290 490 Max. 650
{ } {3.0 5.0}
(Gross)
290 490
70 90 90 110 Max. 650
{ } {3.0 5.0}
(Gross)
290 490
70 90 90 110
{3.0 5.0}
70 90 80 110 Min. 120
{Min. 1.2}
Min. 70 90 90 110 290 490 Max. 650
{ } {3.0 5.0}
(Gross)
290 490
70 90 90 110 Max. 650
{ } {3.0 5.0}
(Gross)
290 490
70 90 90 110
{3.0 5.0}
70 90 80 110 Min. 120
{Min. 1.2}
15W: 343 539
Min. 75 88 80 110 {3.5 5.5} Max. 500
{ } 10W: 294 490
(Gross) {3.0 5.0}
75 88 80 110 Max. 580
{ }
(Gross)
75 88 80 110
75 88 80 110 Min. 147

{Min. 1.5}
114 SERIES 12-121

(5)
TESTING AND ADJUSTING TESTING FUEL FEED PUMP
TESTING FUEL FEED PUMP

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

DISASSEMBLY AND ASSEMBLY OF

FUEL FEED 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)
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.
Fix 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

TESTING AND ADJUSTING ADJUSTING FUEL CUT-OFF SOLENOID
ADJUSTING FUEL CUT-OFF

SOLENOID
DIRECTION OF FUEL CUT-OFF
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 trum-
peter solenoid valves all face in the 6 oclock
direction as specified below.
Check that there is no dirt, damage, or other prob-

lem 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 mount-

ing 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.
ADJUSTING FUEL CUT-OFF

SOLENOID
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 adjust-
ing the trumpeter, so see the procedure on
the following page.
8 mm
As shown in the diagram, adjust the solenoid mount-
ing 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 loosen-
ing 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 move-

ment of the plunger.
1. Synchrostart 2. Trumpeter
A = 86.6 mm A = 91.4 mm
B = 60.2 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 OF MECHANICALLY
OPERATED SOLENOID, CYLINDER
BLOCK
Remove the solenoid link from the lever.
Turn the starting switch ON and check the move-
ment 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 AND ADJUSTING TESTING FOR AIR INSIDE THE FUEL SYSTEM
TESTING FOR AIR INSIDE

THE FUEL 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 fil-
ter and fuel supply line, so if the connection is loos-
ened 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

TESTING AND ADJUSTING TESTING FOR AIR INSIDE THE FUEL SYSTEM
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 AND ADJUSTING TESTING WATER SEPARATOR, FUEL FILTER
TESTING WATER SEPARA-

TOR, FUEL FILTER
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 clear-
ance between the components of the fuel injection
pump is extremely small in some cases.
For that reason, there is danger of damage being
caused by rust or dirt.
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 filter-

ing 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 nec-

essary to periodically drain the moisture from the
fuel and water separator, the filter, or the fuel tank.
12-148 114 SERIES

TESTING AND ADJUSTING TESTING HIGH-PRESSURE FUEL PIPING
TESTING HIGH-PRESSURE
FUEL PIPING
Caution: Fix 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 card-
board.
If any fuel leakage occurs, the engine performance
will drop.
114 SERIES 12-149

TESTING HIGH-PRESSURE FUEL PIPING
TESTING AND ADJUSTING TESTING FUEL 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 rota-
tion will not be smooth and it will cause fuel knock-
ing.
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 FUEL 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 injec-
tion 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. Fuel is injected into the cyl-
inder. 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 AND ADJUSTING TESTING FUEL INJECTION NOZZLE
If the needle valve is not raised or close at the cor-

rect 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 noz-
zle 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 cylin-

der, start the engine, loosen the nut of the fuel injec-
tion 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 injec-
tion 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 work-

ing 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 injec-

tion 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 FUEL DRAIN PIPING
TESTING AND ADJUSTING BLEEDING AIR FROM FUEL SYSTEM
TESTING FUEL DRAIN

PIPING
The fuel system uses fuel to cool and lubricate the
fuel injection pump and fuel injection nozzle. Fuel 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 FROM FUEL

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 automati-
cally 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 FROM LOW-PRES-

SURE CIRCUIT AND FUEL FILTER
Loosen the air bleed plug of the fuel filter.
Operate the hand priming pump until no more bub-

bles come out with the fuel from the air bleed plug in
the fuel filter.
Tighten the joint bolt.
3 Fuel filter air bleed plug: 9 Nm {0.92 kgm}
BLEEDING AIR FROM FUEL INJEC-

TION 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 FROM HIGH-PRES-

SURE 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 injec-
tion 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

TESTING AND ADJUSTING ADJUSTING TIMING OF FUEL INJECTION PUMP
ADJUSTING TIMING OF FUEL

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.
First, 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 posi-
tion 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

TESTING AND ADJUSTING TROUBLESHOOTING DEFECTIVE OPERATION OF COOLING SYSTEM
TIVE OPERATION OF COOL-
ING 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 over-
heating, do not forget that if the level of the oil in the
oil pan is too high, the friction caused when the con-
necting rod journal is immersed in the oil will gener-
ate more heat.
Filling with oil above the specified level will increase
the oil temperature, and this will increase the tem-
perature 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 trans-
fer. If there are excessive bubbles, it will cause con-
centrated 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. For engines with after-
cooler, 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 anti-
freeze 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 cor-
rosion. The small holes in the head gasket
are particularly likely to become clogged.
The holes are orifices and their size is impor-
tant. Do not increase the size of the orifice. If
the orifice is made larger, the flow of the cool-
ing 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 seri-
ous 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 recom-
mended two systems.
System Cap
A (for standard) 104C 103 kPa (1.06 kg/cm2)
B (for light load) 99C 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 overheat-

ing 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. For exam-
ple, the head gasket and oil cooler. (For 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 bot-
tom 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 crank-

shaft 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 run-
ning 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 investi-
gate 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, FAN, 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 operat-
ing 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 oper-
ate at low temperature.
Caution: Check that the temperature sensor is operat-
ing 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 over-
cool.
Caution: Check that the air temperature sensor is
operating correctly. Check the control of the
air pressure actuated shutter. Check for leak-
age 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 circu-
lated repeatedly. Check also that the baffle is
not missing.
THERMOSTAT
The thermostat controls the temperature of the cool-
ing 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 cer-
tain 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 cool-
ing 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 prop-

erly, the engine will overheat or overcool.
As given in the section on the cooling water, be care-

ful 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 over-
cool.
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 FUEL, 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 over-

heat. Check that the fuel injection pump is
adjusted properly.
Caution: Normally, if the engine is overloaded, it will

overheat.
114 SERIES 12-165

TESTING AND ADJUSTING STANDARD VALUE TABLE FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
STANDARD VALUE TABLE FOR TESTING, ADJUSTING, AND

TROUBLESHOOTING
Engine model SAA6D114E-2
Applicable machine model PC300-7, CD110R-2 WA380-5
Cate- Measurement Standard Permissible Standard Permissible

gory Item conditions Unit value value value value
High idling speed rpm 2,180 50 2,180 50 2,250 50 2,250 50

Performance
Engine speed
Low idling speed rpm 900 25 900 25 920 + 50
0 920 + 50
0
Necessary stating 0C (without starting aid) rpm Min. 130 Min. 100 Min. 130 Min. 100
speed 20 (with starting aid) rpm Min. 100 Min. 100 Min. 100 Min. 100
kPa Max. 3.72 7.50 Max. 3.72 7.50
Intake resistance At all speed
{mmH2O} {Max. 380} {762} {Max. 380} {762}
kPa 120 160 93 100 140 73
Boost pressure At rated flywheel horsepower
{mmHg} {900 1,200} {700} {750 1,050} {550}
Intake, exhaust system
Exhaust pressure kPa 135 173 107 107 147 80

At rated flywheel horsepower
(turbine outlet pressure) {mmHg} {1,000 1,300} {800} {800 1,100} {600}
Exhaust temperature
All speed (20C) C Max. 550 600 Max. 550 600
(turbine inlet temp.)
Quick acceleration
Max. 4.5 6.5 Max. 4.5 6.5
(low idle high idle)
Bosch
Exhaust gas color
At rated flywheel horsepower index Max. 1.5 2.5 Max. 1.5 2.5
High idling speed Max. 1.0 2.0 Max. 1.0 2.0
Valve clearance Intake valve mm 0.30 0.30
(When engine is hot or
cold) Exhaust valve mm 0.56 0.56
MPa
Engine proper
Compression pressure Oil temperature: 40 60C Min. 2.4 2.0 Min. 2.4 2.0
{kg/cm2}
(SAE30 or SAE15W-40) (engine speed: 250 rpm) {Min. 24.5} {20.4} {Min. 24.5} {20.4}
(rpm)
Blow-by pressure At rated flywheel horsepower kPa Max. 1.0 2.0 Max. 1.0 2.0
(SAE30 or SAE15W-40) (water temp.: Min. 70C) {mmH2O} {Max. 100} {200} {Max. 100} {200}
At rated flywheel horsepower kPa 290 490 210 290 490 210
SAE30 or SAE15W-40 oil {kg/cm2} {3.0 5.0} {2.1} {3.0 5.0} {2.1}
kPa 250 440 180 250 440 180
SAE10W oil
Oil pressure {kg/cm2} {2.5 4.5} {1.8} {2.5 4.5} {1.8}
Lubrication system
(oil temperature:
Min. 80C) At low idling kPa Min. 120 80 Min. 120 80
SAE30 or SAE15W-40 oil {kg/cm2} {Min. 1.2} {0.8} {Min. 1.2} {0.8}
kPa Min. 100 70 Min. 100 70
SAE10W oil
{kg/cm2} {Min. 1.0} {0.7} {Min. 1.0} {0.7}
All speed
Oil temperature C 80 110 120 80 110 120
(Oil in oil pan)
At continuous rated horsepower
Oil consumption ratio % Max. 0.5 1.0 Max. 0.5 1.0
(Ratio for fuel consumption)
MPa 29.4 30.4 23.5 29.4 30.4 23.5
Fuel injection pressure Nozzle tester
{kg/cm2}
system
{300 310} {240} {300 310} {240}

Fuel
Fuel injection timing B. T. D. C degree 9.5 1 9.5 1 8.5 1 8.5 1
Opening pressure kPa

Radiator pressure valve
Cooling system
(Differential pressure) {kg/cm2}
Fan speed At rated engine speed rpm 1,425 38 1,425 38
Belt tension (Between Deflection when pushed 8 6 10 8 6 10

mm
alternator and idler) with a force of 59 N {6 kg} (Auto tension) (Auto tension) (Auto tension) (Auto tension)
12-200 114 SERIES

(5)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
SAA6D114E-2 SA6D114E-2

GD655-3A,3C GD675-3A,3C
D68ESS-12E0
Standard Permissible Standard Permissible Standard Permissible
value value value value value value
2,250 r 50 2,250 r 50 2,250 r 50 2,250 r 50 2,000 r 50 2,000 r 50

825 r 50 825 r 50 825 r 50 825 r 50 915 r 50 915 r 50
Min. 130 Min. 100 Min. 130 Min. 100
Min. 100 Min. 100 Min. 100 Min. 100
Max. 3.72 7.50 Max. 3.72 7.50 Max. 3.72 6.23
{Max. 380} {762} {Max. 380} {762} {Max. 380} {635}
100 140 73 100 140 73 124 164 97
{750 1,050} {550} {750 1,050} {550} {930 1,230} {730}
107 147 80 107 147 80 10.0 10.0
{800 1,100} {600} {800 1,100} {600} {76} {76}
Max. 580 630
Max. 550 600 Max. 550 600
(Turbine out temp.) (Turbine out temp.)
Max. 4.5 6.5 Max. 4.5 6.5 Max. 6.0 8.0
Max. 1.5 2.5 Max. 1.5 2.5 Max. 1.0 2.0

Max. 1.0 2.0 Max. 1.0 2.0
0.30 0.30 0.30
0.56 0.56 0.56
Min. 2.4 2.0 Min. 2.4 2.0 Min. 2.4 2.0

{Min. 24.5} {20.4} {Min. 24.5} {20.4} {Min. 24.5} {20.4}
Max. 1.0 2.0 Max. 1.0 2.0 Max. 1.5 3.0

{Max. 100} {200} {Max. 100} {200} {Max. 150} {305}
290 490 210 290 490 210 340 540 210
{3.0 5.0} {2.1} {3.0 5.0} {2.1} {3.5 5.5} {2.1}
250 440 180 250 440 180

{2.5 4.5} {1.8} {2.5 4.5} {1.8}
Min. 120 80 Min. 120 80 Min. 120 80
{Min. 1.2} {0.8} {Min. 1.2} {0.8} {Min. 1.2} {0.8}
Min. 100 70 Min. 100 70

{Min. 1.0} {0.7} {Min. 1.0} {0.7}
80 110 120 80 110 120 80 110 120
Max. 0.5 1.0 Max. 0.5 1.0 Max. 0.5 1.0
29.4 30.4 23.5 29.4 30.4 23.5 26.0 27.4 22.1

{300 310} {240} {300 310} {240} {265 279} {225}
8.5 r 1 8.5 r 1 8.5 r 1 8.5 r 1 7r1 7r1
8 6 10 8 6 10

(Auto tension) (Auto tension) (Auto tension) (Auto tension)
114 SERIES 12-201

(6)
TROUBLESHOOTING
TROUBLESHOOTING OF 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 (Fuel is not being injected) ............................ 12-308
(3) Exhaust smoke comes out but engine does not start (Fuel is being injected) ......................... 12-309
S-3 Engine does not pick up smoothly (Follow-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 Fuel 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 OF USING TROUBLESHOOTING CHARTS
METHOD OF USING TROUBLE-

SHOOTING CHARTS
This troubleshooting chart is divided into three sec-
tions: 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 corre-
sponds 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 Causes
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 prob-
ability, starting with the causes that have been (b) (2) (3)
marked as having the highest probability form
information gained from [Questions] and [Check
items].
(a)
Questions
A (b)
(c)
(d)
(e)
B
Check items
i
shooting
Trouble-
ii
iii
12-302 114 SERIES

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 probabil-
ity 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.
Causes
1. For [Confirm Section, ask repair history] in the
[Questions] Section, ask the user, and mark
the Cause column with to use as reference
)n
ctio
for locating the cause of the failure. However,
inje
do not use this when marking calculations to
sive
narrow down the causes.
zle
renc
xces
2. Use the in the Cause column as reference
ner
noz
for [Degree of use (Operated for long period)]
ent
erfe
er li
p (e
g
ion
m
in the [Questions] section as reference.
imin
d
, int
pum
e
n
ject
l
i
er e
As a rule, do not use it when calculating be
, cyl
rger
on t
d in
ion
included if necessary to determine the order
lean
ring
cha
ecti
ject
eize
for troubleshooting.
air c
urbo
r inj
ston
e in
, s
rope
ged
ctiv
ged
n pi
ed t
Defe
Clog
Clog
Wor
Seiz
Imp
1 Confirm recent repair history
2 Degree of use Operated for long period
114 SERIES 12-303

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
Causes
Insufficient intake of air
Improper condition of fuel injection
d)
ad
n)
Excessive injection of fuel
eize
d he
ctio
er s
inje
r an
lung
at
arge
sive
e se
e
ck, p
renc
xces
zzle
och
valv
p (ra
ent
n no
turb
erfe
p (e
lve,
r
r
e
inde
lem
uffle
imin
ranc
, int
pum
pum
ctio
een
f va
er e
, cyl
ed m
rger
inje
clea
on t
etw
ct o
ion
ion
lean
ring
cha
air b
ecti
zed
onta
ject
ject
lve
logg
Legend
air c
urbo
r inj
r va
, sei
ston
e in
e in
c
e of
: Possible causes (judging from Questions and check items)
d, c
e
rope
rope
ged
ctiv
ctiv
ged
ctiv
: Most probable causes (judging from Questions and Check items)
n pi
ed t
she
kag
: Possible causes due to length of use (used for a long period)
Defe
Defe
Defe
Clog
Clog
Wor
Seiz
Imp
Imp
Cru
Lea
: Items to confirm the cause.
Confirm recent repair history
Degree of use Operated for long period
Suddenly became black
Color of exhaust gas Gradually became black
Questions
Blue under light load

Engine oil must be added more frequently
Suddenly
Power was lost
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
When exhaust manifold is touched immediately after
starting engine, temperature of some cylinders is low
Check items
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
Troubleshooting
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
Replace
Adjust
Adjust
Adjust
Repair
Clean
Remedy
12-304 114 SERIES

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
Improper selection of fuel
(At ambient temperature of 10C or below, ASTM
D975 No. 2 diesel fuel is used)
Battery charging rate Causes
Charging rate
Ambient 100 % 90 % 80 % 75 % 70 %
uck)
temperature
er st
20C 1.28 1.26 1.24 1.23 1.22
ank
t
0C 1.29 1.27 1.25 1.24 1.23
ung
l
elem alve sea
ping
ance
t
10C 1.30 1.28 1.26 1.25 1.24
ery
k, pl
fuel
r
el pi
or c
filte
batt
(rac
ve, v
ent
e in
nsat
in fu
The specific gravity should exceed the value for the
er
uze
r
le
inde
eate
ted
rain
l
p
o
nozz
f val
min
mpe
p ga
pum
charging rate of 70% in the above table.
h
, air
iora
, cyl
air h
ump
r, st
her
r
i
aner
tor
act o
nato
t
tion
st co
pum
In cold areas the specific gravity must exceed the
ging
eter
tion
tion
reat
filte
ring
gula
ed p
ake
ir cle
injec
alter
cont
value for the charging rate of 75% in the above table.
or d
boo
clog
injec
injec
air b
feed
fuel
l int
ston
e
r
f
a
ctive
ctive
ctive
ctive
ctive
ctive
ctive
age,
trica
ged
tive
tive
ged
ged
ged
n pi
Defe
Defe
Defe
Defe
Defe
Leak
Defe
Defe
Defe
Defe
Clog
Clog
Clog
Clog
Wor
Elec

Degree of use of machine Operated for long period
Gradually became worse
Ease of starting
Starts when warm
Questions
Indicator lamp does not light up

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
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 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 Yes
with engine at low idling? No
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
Remedy
Use a test stand
12-306 114 SERIES

TROUBLESHOOTING S-2
S-2 Engine does not start
(1) Engine does not turn Causes
General causes why engine does not turn

Seizure inside engine
witc
For seizure inside the engine, carry out the trou-
ctio
it
bleshooting for S-4 Engine stops during opera-
nne
ery
ircu
ty s
batt
tion.
al co
safe
ng c
id
ated
itch
leno
tarti
min
r
y or
Failure in power train
y
o t
rela
g sw
rior
of s
t so
r
rela
Defective electrical system
gm
te
ttery
dete
ttery
el cu
ar
artin
iring
artin
fety
g ge
e ba
e ba
e sa
e or
e fu
e st
e st
ew
r i n
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ken
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Bro
Questions

Condition of horn when Horn sounds
starting switch is turned
ON Horn volume is low
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
Check items
move out
When starting switch is turned to ON, there is no clicking

sound
Battery terminal is loose
Troubleshooting of defective wiring in starting circuit
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
Troubleshooting
2) When terminal B and terminal C of starting motor are

3) When terminal B and terminal C of safety relay are
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
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Remedy
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)
Selection of fuel according to Causes

Type of ambient temperature
fuel 22 4 14 32 50 68 86 104F
d)
eize
30 20 10 0 10 20 30 40C
er s
ASTM D975 No. 2
key
lung
nk
Diesel oil
el ta
aft,
ASTM D975A
ck, p
on
No. 1
e sh
in fu
pist
p (ra
ng
iner
driv
d
ump
hole
pipi
i
If No. 3 diesel oil is not available in winter, it is also
leno
rain
stra
pum
nk
mp
possible to mix No. 2 diesel oil 50:50 with kerosene.
ed p
fuel
r, st
her
t so
in ta
mp
n pu
ed
ion
reat
e
filte
king
l cu
l us
u
en f
fuel
ject
p
ctio
air b
feed
e
r fue
fuel
, lea
brok
e fu
e in
inje
ent
ged
rope
ged
ged
ged
ctiv
ctiv
ffici
ed,
ken
Clog
Defe
Clog
Defe
Clog
Clog
Insu
Seiz
Imp
Bro

Questions

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
When starting switch is turned ON, linkage is not actuated
Check items
When fuel filter is drained, fuel does not come out

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
Troubleshooting
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
Replace
Remedy
12-308 114 SERIES

1
TROUBLESHOOTING S-2
(3) Exhaust smoke comes out but

engine does not start (Fuel is
being injected) Causes
.)
r, etc
General causes why exhaust smoke comes out but
)
tuck
engine not start
leve
cap
er s
y
spra
cker
Lack of rotating force due to defective electri-
lung
tank
em
ater
e, ro
e
cal system
syst
ctiv
k, p
ttery
fuel
i r he
(valv
r
defe
(rac
fuel
nt
er
le in
d ba
i
ke a
l
tem
er
e
r
rain
e
ump
zle,
elem
rain
r in
d
Improper selection of fuel and oil
r ho
rate
e sys
inta
n
p st
noz
i
i
, cyl
r, st
a
on p
terio
e
ner
valv
ed
ical
ing,
h
pum
tion
reat
filte
ring
l us
a
ecti
ectr
e
ken
ogg
e
d
l
njec
air b
eed
air c
r fue
uel
j
ston
e or
, bro
e in
e el
e, cl
f
f
rope
ged
ged
ged
ged
ged
ctiv
ctiv
ctiv
ctive
n pi
kag
Defe
Defe
Defe
Clog
Clog
Clog
Clog
Clog
Wor
Defe
Imp
Lea
Suddenly failed to start
Questions
When engine is cranked, abnormal noise is heard from

around cylinder head
Non-specified fuel is being used
Operation Manual
Indicator lamp does not light up
Starting motor cranks engine slowly
When fuel lever is placed at FULL position, it does not contact stopper
Check items
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
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 fuel filter, strainer are inspected directly, they are
Troubleshooting
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
Replace
Replace
Replace
Replace
Correct
Correct
Clean
Clean
Clean
Clean
Clean
Remedy
114 SERIES 12-309

TROUBLESHOOTING S-3
S-3 Engine does not pick up smoothly

(Follow-up is poor)
General causes why engine does not pick up smoothly Causes

ap
y
seat
spra
nk c
Improper fuel used
lve
el ta
tive
nce
d va
er
efec
ger
in fu
fere
r lin
e an
ent
ng
er
n
d
r
nter
rain
aine
pipi
e
hole
e
lem
zle,
p pl
valv
anc
d
cylin
er, i
p st
noz
r
er e
fuel
pum
r, st
r
her
clea
t of
pum
harg
n
lean
ng,
reat
filte
king
ntac
ctio
tion
lve
i
c
r
air b
eed
air c
urbo
uel
, lea
inje
r va
ston
e co
njec
f
f
rope
ged
ged
ged
ged
ged
ged
ctiv
ed t
ed i
n pi
Clog
Clog
Clog
Defe
Clog
Clog
Clog
Seiz
Seiz
Wor
Imp
Questions
Operation Manual
Engine pick-up suddenly became poor
Color of exhaust gas
Black
Check items

High idling speed under no load is normal, but speed
suddenly drops when load is applied
When air cleaner element is inspected directly, it is found to

be clogged
found to be clogged
When feed pump strainer is inspected directly, it is found to be
Troubleshooting
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
When feed pump is operated, operation is too light or too heavy
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Clean
Clean
Clean
Clean
Remedy
12-310 114 SERIES

TROUBLESHOOTING S-4
S-4 Engine stops during operations

General causes why engine stops during operations Causes
Seized parts inside engine
c.)
r , et
)
tuck
leve
Overheating
er s
cker
If the is overheating and the engine stops,
rod
lung
nk
e, r o
el ta
carry out troubleshooting for overheating.
nt
ey
ring
ting
ck, p
ston
(valv
e
ft, k
ui pm
in fu
(See S-14 Water temperature becomes too
a
nec
p pi
ft be
p ( ra
ng
iner
sha
high)
stem
iner
con
y eq
ole
pipi
pum
in
stra
ksha
pum
e
stra
nk
r tra
er h
v
e sy
in
on,
iliar
Failure in power train
fuel
p dr
in ta
r t ra
ump
feed
cran
valv
eath
gea
ion
pist
ter,
x
king
pum
p au
If the engine stops because of a failure in
owe
uel
ject
ed p
l
zed
i
c
zed
zed
r
zed
f
i
air b
ynam
fuel
, lea
f
the power train, carry out troubleshooting
pum
e in
in p
fuel
, sei
ent
, sei
, sei
, sei
f e
for the chassis.
ged
ged
ged
ged
ctiv
en d
ffici
ken
ure
ken
ken
ken
ken
ken
Clog
Clog
Defe
Clog
Clog
Insu
Brok
Fail
Bro
Bro
Bro
Bro
Bro
Bro
Abnormal noise was heard and
engine stopped suddenly
Condition when engine
Questions
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
Fuel level lamp lights up
Engine rotates, but stops when power train is operated
Check items
Does not turn at all

When it is attempted to Turns in opposite direction
turn by hand using
barring tool Moves amount of backlash
Shaft does not turn
Troubleshooting of chassis
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
found to be clogged
When feed pump strainer is inspected directly, it is found to
be clogged
Inspect feed pump directly
does not return
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Remedy
Add
114 SERIES 12-311

TROUBLESHOOTING S-5
S-5 Engine does not rotate smoothly

(Hunting)
General causes why engine does not rotate smoothly Causes
Air in fuel system
p
zzle
pum
Defective governor mechanism
d no
eed
Defective electric governor mechanism
p an
nd f
(engine with electric governor)
pum
nk a
nk
el ta
If hunting stops when electric governor rod is
el ta
r
c
erno
feed
ol ra
rnor
disconnected, carry out troubleshooting for the
in fu
n fu
iner
gov
een
ontr
ove
in ta low
troubleshooting for electric system.
er
tw ee
hole
betw
rain
stra
of g
t of
of c
o
k
it be
o
n
r, st
her
men
ump
rcuit
ion
ion
d is
circu
reat
filte
erat
erat
just
i
fuel
ed p
c
e
air in
air b
g sp
air in
fuel
e ad
e op
e op
ent
f e
idlin
ged
ged
ged
ged,
ctiv
ged,
ctiv
ctiv
ffici
Clog
Clog
Clog
Defe
Defe
Defe
Clog
Insu
Clog
Low
Occurs at a certain speed range
Questions
Occurs at low idling

Condition of hunting
Occurs even when speed is raised
Occurs on slopes
to Operation Manual
Rust, water are found when fuel tank is drained
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
When governor lever is moved it is found to be stiff

When injection pump is tested, governor is found to be
Troubleshooting
improperly adjusted
does not return
When feed pump strainer is inspected directly, it is
found to be clogged
found to be clogged
Correct
Correct
Adjust
Adjust
Adjust
Adjust
Clean
Clean
Clean
Remedy
Add
12-312 114 SERIES

TROUBLESHOOTING S-6
S-6 Engine lacks output

(or lacks power) Causes
General causes why engine lacks output
ent
stm
m
y
seat
spra
hrag
adju
tank
lve
tive
diap or diap
e
d va
fuel
renc
ctiv
efec
m
er
Improper fuel used
e an
hrag
ung
g
n
ent
defe
er
erfe
sat
le, d
ipin
i
pum ainer
(if non-specified fuel is used, output drops)
rain
hole
e
i nde
lem
p pl
valv
pen
ranc
, int
p
ge,
z
Lack of output due to overtaking
p st
noz
tr
fuel
er e
pum
, cyl
her
com
rger
er, s
nka
t of
clea
ate
i on
reat
lean
If there is overheating and lack of output,
king
ring
c
er li
estg
cha
tion
t
ost
a
lve
l
ject
i
t
f
air b
carry out troubleshooting for S-14 overheat-
feed
air c
l lev
fuel
urbo
, lea
e bo
e co
r va
ston
njec
ew
n
ing.
t fue
rope
ged
ged
ged
ctiv
ged
ged
ctiv
ged
ctiv
ed t
n pi
ed i
Defe
Clog
Clog
Clog
Defe
Defe
Clog
Clog
Clog
Seiz
Seiz
Wor
Ben
Imp
Suddenly
Power was lost
Gradually
Questions

to Operation Manual
Black
Check items
High idling speed under no load is normal, but speed

suddenly drops when load is applied
High idling speed of engine is low
When air cleaner element is inspected directly, it is found to be

clogged
found to be clogged
Troubleshooting
When feed pump strainer is inspected directly, it is found

to be clogged
is stopped
does not return
When valve clearance is checked directly, it is found to be
When lever is placed at FULL position, it does not contact stopper
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Adjust
Clean
Clean
Clean
Clean
Remedy
114 SERIES 12-313

TROUBLESHOOTING S-7
S-7 Exhaust smoke is black

(Incomplete combustion)
General causes why exhaust smoke is black Causes
d)
ad
)
tion
eize
d he
njec
er s
at
ray
r an
e se
lung
e sp
ve i
arge
valv
essi
e
ctiv
ck, p
renc
och
er
and
(exc
defe
r lin
p ( ra
ent
turb
erfe
lve
g
r
ce
i nde
mp
lem
zle,
uffle
imin
, int
pum
een
aran
f va
u
z
er e
, cyl
n no
ed m
rger
on t
w
ct o
e cle
ion
ion
t
lean
ir be
ring
ctio
cha
ecti
onta
ject
ject
logg
valv
air c
a
inje
urbo
r inj
ston
e in
e in
c
e of
d, c
e
r
rope
rope
ged
ctiv
ctiv
ged
ctiv
n pi
ed t
she
kag
Defe
Defe
Defe
Clog
Clog
Wor
Seiz
Imp
Imp
Cru
Lea
Suddenly became black
Color of exhaust gas Gradually became black
Questions

Suddenly
Power was lost
Gradually
When exhaust manifold is touched immediately after
starting engine, temperature of some cylinders is low
Check items
Timing lock on fuel injection pump does not match

Exhaust noise is abnormal
Muffler is crushed
Leakage of air between turbocharger and head, loose clamp

When air cleaner element is inspected directly, it is found to be
clogged
Troubleshooting

is stopped
When check is made using delivery method, injection timing
is found to be incorrect
When valve clearance is checked directly it is found to be
When muffler is removed, exhaust color returns to normal
does not return
Replace
Replace
Replace
Replace
Replace
Replace
Remedy
Correct
Adjust
Adjust
Adjust
Clean
12-314 114 SERIES

TROUBLESHOOTING S-8
S-8 Oil consumption is excessive

(or exhaust smoke is blue)
Do not run the engine at idling for more than 20 Causes
minutes continuously. (Both low and high idling)
r
arge
General causes why oil consumption is excessive
och
Abnormal combustion of oil
Turb
al
External leakage of oil
d
hea
n se
ce
em
e
Wear of lubrication system
oler
urfa
hos
der
oke
syst
er
s
r lin
cylin
her
), br
seal
pl ug
r oi l
e
reat
k
inde
d
nd
uide
inta
n or
ter o
pi ng
eal,
n
ain
e
er e
or b
, cyl
bine
m, g
om
ar s
il pa
il dr
il pi
il fil
ing
low
ther
r
ring
in fr
n re
oole
t tur
(ste
mo
mo
mo
mo
on r
at b
brea
roke
ston
cked
al a
oil c
e fro
e fro
e fro
e fro
lve
pist
a l
n va
n se
n se
ged
n, b
n pi
t su
kag
ken
kag
kag
kag
ken
Clog
Wor
Wor
Wor
Wor
Wor
Dus
Lea
Bro
Lea
Lea
Lea
Confirm recent repair history Bro
Oil consumption suddenly increased
Questions
Engine oil becomes contaminated quickly

Exhaust smoke is blue under light load
Excessive
Amount of blow-by gas
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 breather element is inspected, it is found to be
Troubleshooting
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
Correct
Clean
Remedy
114 SERIES 12-315

TROUBLESHOOTING S-9
S-9 Oil becomes contaminated quickly

General causes why oil becomes contaminated quickly Causes
Entry of exhaust gas due to internal wear
Clogging of lubrication passage
Improper fuel
end
Improper oil used
e
rbin
Operation under excessive load
tube
er tu
se
er
ain
o
r lin
harg
i l dr
r
athe
inde
er o
ui de
boc
lack
, bre
, cyl
harg
t tur
g
is b
r
e
ther
o ol e
ring
valv
r
al a
e
rboc
oke
t
il fil
brea
oil c
ston
e se
lve,
t sm
u
o
t
ged
n va
ged
ged
ged
ctiv
n pi
aus
Clog
Defe
Clog
Clog
Clog
Wor
Wor
Exh
Questions

Non-specified oil is being used
Black
Carry out troubleshooting for S-7 Exhaust smoke is black.

Excessive
Amount of blow-by gas
Check items
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 breather element is inspected directly, hose is
broken or is found to be clogged with dirty oil
Troubleshooting
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
Replace
Clean
Clean
Clean
Remedy
12-316 114 SERIES

TROUBLESHOOTING S-10
S-10 Fuel consumption is excessive

General causes why fuel consumption is excessive Causes
Leakage of fuel
)
tion
ge
ter
on)
njec
linka
el fil
(pist
ive i
g, fu
trol
mp
r
er
cess
cove
l con
pipin
d pu
ng
ng
y
p plu
p (ex
spra
f fue
ead
timi
e
fuel
f e
pum
h
pum
e
lder
nt o
tion
nsid
from
side
le ho
stme
injec
tion
eal i
el in
o
age
ti
injec
injec
nozz
adju
oil s
fuel
of fu
leak
ctive
ctive
ctive
ctive
ctive
ctive
age
rnal
Defe
Defe
Leak
Defe
Defe
Defe
Defe
Exte
Questions

More than for other machines of same
Condition of fuel model
consumption Gradually increased
Suddenly increased
Black
Exhaust smoke color
White
There is irregular combustion
Check items
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

Troubleshooting
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 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
Adjust
Remedy
114 SERIES 12-317

S-11 Oil is in cooling water, or water

spurts back, or water level goes
down
General causes why oil in cooling water Causes
Internal leakage in lubrication system

Internal leakage in cooling system
et
gask
k
bloc
ing
ler
head
l coo
, O-r
der
g
cylin
ittin
core
ead,
in oi
by p
er h
r tra
oler
s in
ylind
rack
used
owe
il co
nal c
en o
en p
en c
s ca
Brok
Brok
Hole
Brok
Inter
Questions

Suddenly increased
Oil level
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
shooting
Trouble-

Pressure-tightness test of cylinder head shows there is leakage
Replace
Replace
Replace
Replace
Replace
Remedy
12-318 114 SERIES

S-12 Oil pressure caution lamp lights

up (Drop in oil pressure)
General causes why oil pressure lamp lights up
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
Selection of SAE No. according to Causes

Type of oil ambient temperature
`! ` ` ! "+
SAE30CD
SAE10WCD
Engine oil
g
ipin
SAE10W-30CD
n
n
il pa
sor
l pa
lic p
ing
SAE15W-40CD
n
e oi
sor
alve
de o
drau
braz
e se
l
sen
d
urna
e
tor v
ssur
insi
insi
d hy
n
ipe
valv
mp
il pa
l
eve
g, jo
on p
il
ilter
iner
l pre
gula
ipe
she
l pu
in o
lief
in o
l
oil p
stra
oil f
l
arin
, cru
e re
e re
e oi
e oi
e oi
suct
uel
i l
of o
n be
ctiv
ctiv
ged
ged
ctiv
ged
ctiv
ctiv
king
er, f
ken
Defe
Defe
Defe
Defe
Defe
Lack
Clog
Clog
Clog
Wor
Wat
Lea
Bro

Questions

Operation Manual
Caution lamp lights up
Lights up at low idling
Condition when oil Lights up at low, high idling
pressure lamp lights up
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 stuck to oil filter element
Oil is cloudy white or smells of diesel oil
Carry out troubleshooting
for S-13 Oil level rises.
When oil filter is inspected, it is found to be clogged

Troubleshooting

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
Replace
Correct
Correct
Adjust
Adjust
Clean
Clean
Clean
Clean
Remedy
Add
114 SERIES 12-319

S-13 Oil level rises (Water, fuel in oil)

If there is oil in the cooling water, carry out trouble- Causes
shooting for S-11 Oil is in cooling water, or water
level goes down.
ver
General causes why oil level rises
d co
seal
hea
Water in oil (milky white)
ent
mp
ket
side
Fuel in oil (diluted, and smells of diesel fuel)
i pm
ace
n pu
gas
Entry of oil from other component
g in
surf
-ring
equ
leev
ctio
k
ead
bloc
n
seal
pi pi
ary
s
e
re, O
d, h
j
r
n
e
g
i
der
hold
l
from
ittin
stat
rear
side
aux
hea
r co
cylin
rmo
by p
rt in
zzle
oole
ged
mp
der
fuel
side
e
e no
e pu
cylin
e pa
ama
ade
e th
oil c
e of
ks in
sm
ctiv
ctiv
ctiv
ctiv
n, d
kag
ken
ken
Defe
Hole
Defe
Defe
Defe
Crac
Wor
Lea
Bro
Confirm recent repair history Bro
Questions

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,
Check items
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 cylinder head shows there is leakage
Troubleshooting

Inspect rear seal directly
When pump auxiliary equipment is removed, seal is found to
be damaged
Remove injection pump and inspect directly
Defective contact with thermostat seal valve
Remove oil pan and check directly
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
12-320 114 SERIES

S-14 Water temperature becomes too

high (Overheating)
General causes why water temperature becomes too Causes
high
Lack of cooling air (deformation, damage of fan)
Drop in heat dissipation efficiency
re
Defective cooling circulation system
ratu
en)
Rise in oil temperature in power train
ket
mpe
t op
aug
lley
gas
Carry out troubleshooting for chassis.
re g
ns
s no
n pu
il te
or fi
ead
u
er o
doe
ool e
rn fa
t
alve
pera
diat
d, h
tat (
vert
g
core
er
oil c
, wo
ittin
re v
d ra
hea
ump
tem
wat
mos
con
ator
by p
essu
ping
ken
she
der
ater
er p
rque
ther
, bro
radi
, cru
ooli
cylin
p
e pr
ade
ew
wat
s l i
in to
e
of c
ged
ged
ged
sm
ctiv
ctiv
ctiv
belt
ken
ken
Clog
Defe
Hole
Clog
Defe
Lack
Clog
Defe
Rise
Bro
Bro
Fan
Questions
Suddenly overheated
Condition of overheating
Always tends to overheat
Water temperature Rises quickly
gauge 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
Engine oil level has risen, oil is cloudy white
Check items
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
Temperature difference between top and bottom radiator tanks

Carry out troubleshooting for chassis.
is excessive
Temperature difference between top and bottom radiator tanks
is slight
Troubleshooting
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
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
Add
114 SERIES 12-321

S-15 Abnormal noise is made

Judge if the noise is an internal noise or an external Causes
noise.
ead
etc.)
)
General causes why abnormal noise is made
ition
d)
der h
i on)
ver,
eize
f pos
ject
cylin
er le
Abnormality due to defective parts
er s
ce
n
out o
r
Abnormal combustion
rock
aran
r line
l ung
r and
ive
e
Air sucked in from intake system
c
e
oard
e cle
cess
linde
alve
eren
ck, p
enc
arge
pum oz z l e
m (v
ing b
sh
x
r
g, cy
valv
f
p (ra
boch
e
r
p (e
inte
f
nn
ckla
nter
yste
divid
n rin
i ng
t of
pum
n tur
ctio
a
belt
er, i
b
lve s
ush
n
pisto
fler (
i nj e
train
wee
e
i on
i on
harg
n
m
ic va
b
n, fa
just
muf
r bet
d
r of
ject
ject
zed
r
e
a
c
ynam
z
wea
urbo
r ge
d fa
e ad
, sei
e in
of ai
side
, sei
e in
rme
rope
ssive
ctiv
ged
ctiv
ct in
en d
ctiv
ed t
sing
age
Defe
Defo
Defe
Defe
Clog
Defe
Brok
Leak
Seiz
Imp
Exce
Mis
Questions
Condition of abnormal Gradually occurred

noise Suddenly occurred
Black
Metal particles are found in oil filter
Engine pickup is poor and combustion is abnormal
Check items

Abnormal noise is loud when accelerating engine
Leakage of air between turbocharger and cylinder head, loose clamp
Vibrating noise is heard from around muffler

Remove gear cover and inspect directly
Speed does not change when operation of certain cylinders is
Troubleshooting
stopped
When control rack is pushed, it is found to be heavy, or does
not return
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
Replace
Correct
Correct
Correct
Remedy
12-322 114 SERIES

S-16 Vibration is excessive

If there is abnormal noise together with the vibra- Causes
tion, carry out troubleshooting also for S-15
tuck)
n)
Abnormal noise is made.
ctio
etc. s
i on
ned
i nj e
General causes why vibration is excessive
ush
ver,
alig
per)
fuel
en c
ker le
Defective parts (abnormal wear, breakage)
mis
dam
sive
ring
brok
, roc
Improper alignment
n
aft (
xces
bea
a i
valve
Abnormal combustion
er tr
lts,
h
t sh
klas
ain
p (e
g bo
(
pow
m
utpu
d, m
e
bac
pum
st
ntin
y
and
lve s
de o
g ro
n
ing
u
i on
i
r tra
o
ic va
g i ne
m
ctin
insi
ject
s
gea
u
ynam
e
nne
ngin
b
f en
e in
part
m
r
d
n co
rope
ter o
n ca
ctiv
se e
ctive
ken
Defe
Wor
Wor
Imp
Cen
Loo
Defe
Bro
Questions
Suddenly increased
Condition of vibration
Gradually increased
Metal particles are found in oil filter
Oil pressure is low at low idling
Check items
Vibration occurs at mid-range speed

Vibration follows engine speed
Exhaust smoke is black

Remove side cover and inspect directly
Troubleshooting
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
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Remedy
114 SERIES 12-323

13 DISASSEMBLY AND
ASSEMBLY
SPECIAL TOOL LIST .................................... 13- 4 REMOVAL OF AFTERCOOLER ............. 13- 17

SPECIAL TOOLS FOR DISASSEMBLY REMOVAL OF
AND ASSEMBLY............................. 13- 4 FUEL DRAIN MANIFOLD ................ 13- 18
OUTLINE OF DISASSEMBLY REMOVAL OF INJECTOR ...................... 13- 18
AND ASSEMBLY OF ENGINE ............... 13- 8 REMOVAL OF
OUTLINE ................................................ 13- 8 CYLINDER HEAD COVER .............. 13- 19
OVERALL DISASSEMBLY OF ENGINE ....... 13- 9 REMOVAL OF ROCKER LEVER............ 13- 19
ENGINE LIFTING TOOL REMOVAL OF PUSH ROD ..................... 13- 20
AND BRACKET ............................... 13- 9 REMOVAL OF TURBOCHARGER
PREPARATION FOR OIL SUPPLY HOSE ......................... 13- 20
STEAM CLEANING OF ENGINE .... 13- 9 REMOVAL OF TURBOCHARGER
STEAM CLEANING OF ENGINE ........... 13- 9 OIL DRAIN TUBE............................. 13- 20
DRAINING OIL........................................ 13- 10 REMOVAL OF TURBOCHARGER.......... 13- 20
DRAINING COOLANT ............................ 13- 10 REMOVAL OF EXHAUST MANIFOLD.... 13- 21
REMOVAL OF OIL FILTER..................... 13- 10 REMOVAL OF DRIVE BELT ................... 13- 21
REMOVAL OF FUEL FILTER................. 13- 11 REMOVAL OF BELT TENSIONER ......... 13- 21
REMOVAL OF FUEL SUPPLY PIPE REMOVAL OF
(LOW-PRESSURE SIDE)................ 13- 11 BELT TENSIONER BRACKET......... 13- 21
REMOVAL OF FUEL FEED PUMP ........ 13- 11 REMOVAL OF
REMOVAL OF FUEL SUPPLY PIPE ALTERNATOR BRACKET................ 13- 22
(HIGH-PRESSURE SIDE) ............... 13- 12 REMOVAL OF ALTERNATOR................. 13- 22
REMOVAL OF FUEL INJECTION PUMP REMOVAL OF
FUEL SUPPLY PIPES ..................... 13- 12 ALTERNATOR BRACKET................ 13- 22
REMOVAL OF BOOST REMOVAL OF COOLANT
COMPENSATOR TUBE .................. 13- 12 OUTLET CONNECTOR ................... 13- 22
REMOVAL OF TACHOMETER DRIVE... 13- 13 REMOVAL OF
REMOVAL OF COOLANT AIR BLEED TUBE.......... 13- 23
FUEL INJECTION PUMP ................ 13- 13 REMOVAL OF
REMOVAL OF AIR COOLANT AIR BLEED VALVE ........ 13- 23
CONDITIONER COMPRESSOR..... 13- 14 REMOVAL OF
INSTALLATION OF ENGINE THERMOSTAT AND HOUSING....... 13- 23
TO ENGINE STAND ........................ 13- 15 REMOVAL OF
REMOVAL OF THERMOSTAT AND HOUSING....... 13- 23
TURBOCHARGER EXHAUST REMOVAL OF CYLINDER HEAD ........... 13- 24
OUTLET CONNECTOR .................. 13- 16 DRAINING OIL FROM OIL COOLER...... 13- 24
REMOVAL OF WESTGATE REMOVAL OF
ACTUATOR HOSE .......................... 13- 16 COOLANT INLET CONNECTOR..... 13- 24
REMOVAL OF CYLINDER BLOCK REMOVAL OF FAN HUB ASSEMBLY .... 13- 25
BREATHER TUBE........................... 13- 16 REMOVAL OF WATER PUMP................ 13- 25
REMOVAL OF CROSSOVER TUBE ...... 13- 17 REMOVAL OF VIBRATION DAMPER..... 13- 26
REMOVAL OF INTAKE REMOVAL OF GEAR COVER ................ 13- 26
MANIFOLD COVER ........................ 13- 17
114 SERIES 13-1

REMOVAL OF MEASURING PISTON RING
FRONT CRANKSHAFT SEAL ......... 13- 26 END GAP ......................................... 13- 53
REMOVAL OF STARTING MOTOR........ 13- 26 INSTALLATION OF PISTON RING ......... 13- 54
REMOVAL OF COOLANT HEATER ....... 13- 27 INSTALLATION OF
REMOVAL OF FLYWHEEL..................... 13- 27 PISTON ASSEMBLY ........................ 13- 56
REMOVAL OF FLYWHEEL HOUSING ... 13- 27 INSTALLATION OH GEAR HOUSING .... 13- 61
REMOVAL OF OIL PAN ......................... 13- 27 INSTALLATION OF OIL PUMP................ 13- 62
REMOVAL OF SUCTION TUBE............. 13- 28 INSTALLATION OF CAMSHAFT ............. 13- 64
REMOVAL OF INSTALLATION OF WATER PUMP......... 13- 66
REAR CRANKSHAFT SEAL............ 13- 28 INSTALLATION OF
REMOVAL OF CAMSHAFT .................... 13- 28 OIL SUCTION TUBE ........................ 13- 66
REMOVAL OF VALVE TAPPET .............. 13- 30 INSTALLATION OF
MEASUREMENT OF REAR CRANKSHAFT SEAL ............ 13- 66
OIL PUMP GEAR BACKLASH ........ 13- 30 INSTALLATION OF WEAR SLEEVE,
REMOVAL OF OIL PUMP....................... 13- 31 REAR CRANKSHAFT SEAL ............ 13- 67
REMOVAL OF INSTALLATION OF OIL PAN .................. 13- 70
ENGINE FRONT SUPPORT ........... 13- 31 INSTALLATION OF
REMOVAL OF GEAR HOUSING............ 13- 31 TIMING PIN ASSEMBLY.................. 13- 71
REMOVAL OF CARBON ACCUMULATED INSTALLATION OF
ON CYLINDER LINER..................... 13- 32 FLYWHEEL HOUSING..................... 13- 74
REMOVAL OF PISTON ASSEMBLY ...... 13- 33 TESTING COAXIALITY OF
REMOVAL OF PISTON PIN.................... 13- 34 FLYWHEEL HOUSING BORE ......... 13- 75
REMOVAL OF PISTON RING................. 13- 34 INSTALLATION OF FLYWHEEL.............. 13- 79
REMOVAL OF MAIN BEARING CAP ..... 13- 35 MEASURING RUNOUT OF
REMOVAL OF MAIN BEARING FLYWHEEL BORE ........................... 13- 81
(LOWER) ......................................... 13- 35 MEASURING FACE
REMOVAL OF CRANKSHAFT................ 13- 36 RUNOUT OF FLYWHEEL ................ 13- 83
REMOVAL OF INSTALLATION OF
MAIN BEARING (UPPER) ............... 13- 36 STARTING MOTOR ......................... 13- 84
REMOVAL OF INSTALLATION OF OIL COOLER........... 13- 84
PISTON COOLING NOZZLE ........... 13- 36 INSTALLATION OF OIL FILTER.............. 13- 85
TESTING PROTRUSION OF INSTALLATION OF CYLINDER HEAD.... 13- 85
CYLINDER LINER ........................... 13- 36 INSTALLATION OF PUSH ROD.............. 13- 89
REMOVAL OF CYLINDER LINER .......... 13- 37 ASSEMBLY OF ROCKER LEVER
REPLACEMENT OF AND SHAFT ..................................... 13- 89
EXPANSION PLUG ......................... 13- 38 INSTALLATION OF
REMOVAL OF EXPANSION PLUG ........ 13- 38 ROCKER LEVER ASSEMBLY ......... 13- 91
REMOVAL OF CYLINDER BLOCK ADJUSTING VALVE CLEARANCE ......... 13- 92
FROM ENGINE STAND .................. 13- 39 INSTALLATION OF HEAD COVER ......... 13- 94
ASSEMBLY OF ENGINE............................... 13- 40 INSTALLATION OF CYLINDER BLOCK
INSTALL THE CYLINDER BLOCK BREATHER TUBE............................ 13- 95
TO THE ROLL-OVER STAND......... 13- 40 INSTALLATION OF INJECTOR............... 13- 95
INSTALLATION OF CYLINDER LINER .. 13- 40 INSTALLATION OF
INSTALLATION OF TAPPET .................. 13- 45 FUEL DRAIN MANIFOLD................. 13- 96
INSTALLATION OF INSTALLATION OF
PISTON COOLING NOZZLE ........... 13- 45 ENGINE LIFTING BRACKET ........... 13- 96
INSTALLATION OF INSTALLATION OF
MAIN BEARING (UPPER) ............... 13- 46 INTAKE MANIFOLD COVER ........... 13- 96
INSTALLATION OF CRANKSHAFT ........ 13- 48 INSTALLATON OF AFTERCOOLER ....... 13- 97
INSTALLATION OF INSTALLATON OF
MAIN BEARING (LOWER) .............. 13- 49 EXHAUST MANIFOLD ..................... 13- 97
INSTALLATION OF INSTALLATION OF TURBOCHARGER .. 13- 98
MAIN BEARING CAP ...................... 13- 49 INSTALLATION OF TURBOCHARGER
INSTALLATION OF OIL DRAIN TUBE ............................. 13- 99
CONNECTING ROD BOLT.............. 13- 52 INSTALLATION OF TURBOCHARGER
INSTALLATION OF PISTON PIN............ 13- 53 OIL SUPPLY HOSE......................... 13-101
13-2 114 SERIES

INSTALLATION OF TURBOCHARGER INSTALLATION OF FUEL PIPING TUBE
EXHAUST OUTLET PORT (LOW-PRESSURE SIDE) ................ 13-119
CONNECTOR................................... 13-101 INSTALLATION OF
INSTALLATION OF CROSSOVER ......... 13-101 FUEL PUMP SOLENOID ................. 13-119
INSTALLATION OF THERMOSTAT INSTALLATION OF AIR COMPRESSOR 13-119
AND HOUSING ............................... 13-101 INSTALLATION OF
INSTALLATION OF COOLANT ENGINE ACCESSORY .................... 13-121
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
114 SERIES 13-3

SPECIAL TOOL LIST DISASSEMBLY AND ASSEMBLY
SPECIAL TOOL LIST

SPECIAL TOOLS FOR DISASSEMBLY AND ASSEMBLY
Standard Puller
ST-647 Used to remove drive pulleys, impellers, air compressor
counterweights, etc.
Cylinder Liner Driver

ST-1229
Install cylinder liner in cylinder block.
Dial Gauge Attachment

Attaches to crankshaft flange to provide measuring of
ST-1325
flywheel and flywheel housing runout with dial bore
gauge.
Cup Plug Sealant

3375068 Used when installing pipe plugs, cup plugs, etc. on the
engine to prevent leaks.
Dial Bore Gauge Kit

3375072 Used to measure internal diameter bores from 78.5 mm
[3.09 in] to 203.2 mm [8.0 in].
Universal Cylinder Liner Puller

3375629 Remove cylinder liners from cylinder block. Requires
Part No. 3822786 Cylinder Liner Puller Plate.
13-4 114 SERIES

DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
Oil Filter Wrench

3375049
Used to remove and install the lubricating oil filters.
Engine Stand
3375194 Used to support engine block when assembling engine.
Used together with adapter plate (Part No. 3822607).
Nylon lifting sling

3375957 Used as an aid when removing or installing crankshaft,
flywheel, or other heavy components.
Cylinder Liner Puller (Universal)

Remove cylinder liners from the cylinder block.
3376015
Requires two Part No. 3376649 Puller Arm Extension
Feet.
Dial Indicator and Sleeve Assembly

Use with Part No. ST-1325 Dial Gauge Attachment to
3376050 measure fly wheel and flywheel housing runout.
Use with magnet base (Part No. 3377399) to provide
measuring of gear end clearance and backlash.
Engine Barring Gear

3377371 Used to engage the flywheel ring gear to rotate the
crankshaft.
Magnet base dial indicator holder

3377399 Used together with dial indicator and sleeve assembly
(Part No. 3376050).
114 SERIES 13-5

SPECIAL TOOL LIST DISASSEMBLY AND ASSEMBLY
Cylinder Liner Clamp Set

Used to clamp the liner into the bore of the cylinder
3822503 block.
Note: Requires two cylinder head capscrews (not
included in the clamp set).
Engine lifting tool

3822512
Used when lifting engine.
Adapter plate
3822607 Used when installing engine to engine stand (Part No.
3375194).
Piston Ring Expander

3823137 Used to install piston rings onto pistons without damag-
ing or distorting the rings.
Fuel Pump Gear Puller

3824469
Used to pull the fuel pump gear.
Injector Puller
3823276
Used to pull injectors.
Piston Ring Compressor

3823290 Used to compress the piston rings while installing the
pistons into the cylinder bores.
13-6 114 SERIES

DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
Crowfoot Wrench
3823425 Used to torque high pressure fuel line nuts on Aor MW
Bosch fuel pump. Size: 10 mm, 17 mm, 3/8 in. drive.
Sealant, Three Bond (150 Gram Tube)

3823494
Used for sealing T joints and front gear cover.
Gauge Block
3823495
Measure cylinder liner protrusion on the cylinder block.
Main Bearing Rollout Tool

3823818 Used to remove and install main bearings with the
crankshaft installed.
Torque angle gauge

3823878 Used when applying torque to mounting bolts using
torque + angle method.
Wear sleeve screwdriver

3823908 Used when installing front crankshaft oil seal wear
sleeve.
Fuel injection pump installation tool kit

3823956 Used when removing or installing mounting bolts inside
fuel injection pump body.
114 SERIES 13-7

OUTLINE OF DISASSEMBLY AND ASSEMBLY OF ENGINE DISASSEMBLY AND ASSEMBLY
OUTLINE OF DISASSEMBLY AND ASSEMBLY OF ENGINE

OUTLINE The torque values for each procedure are given.
The procedure explained below is for the 114 series Many gaskets and O-rings are made from material
engine. The explanation also mentions differences designed to absorb oil. If the gaskets or O-rings
in the engine model because of the purpose, come into contact with oil, they expand and the seal-
optional equipment for the engine, and the year of ing effect is increased. When installing these parts,
assembly of the engine. Omit any procedure that is use only the recommended adhesive or vegetable
not related to your engine. oil.
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 met-
ric system. Basically, all fasteners have right-
hand 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 O-
rings. If they are necessary for analysis of any fail-
ure, keep these parts in a safe place. When remov-
ing the parts , fix labels, tags, or make marks to
show the position of the part. This helps in identify-
ing 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 proce-
dure. 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 compo-
nents and assemblies have been cleaned, replaced,
and reassembled, and that preparations have been
made to install them to the engine.
13-8 114 SERIES

DISASSEMBLY AND ASSEMBLY OVERALL DISASSEMBLY OF ENGINE
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 stan-
dard 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 compo-
nents to prevent damage caused by water.
STEAM CLEANING OF ENGINE

Warning:When cleaning with steam, wear protec-
tive 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 out-
side of the engine.
114 SERIES 13-9

OVERALL DISASSEMBLY OF ENGINE DISASSEMBLY AND ASSEMBLY
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 (LOW-

PRESSURE 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 (HIGH-

PRESSURE 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-pres-
sure 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 COM-

PRESSOR
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).
Tightening
Bolt position Bolt size
torque value
A M8 24 Nm {2.4 kgm}
B, C M10 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 (SA6D114E-
2).
REMOVAL OF AFTERCOOLER
8mm
Remove the coolant supply tube and the coolant
return tube (SA6D114E-2).
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 SUP-

PLY 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 CONNEC-

TOR
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).
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 cam-
shaft gear and crankshaft gear to carry out investi-
gation.
Limit of camshaft gear backlash
mm
Min. 0.080
Max. 0.33
When investigating the backlash, if the contact-

ing gears are not held in position, the measure-
ment 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 cyl-

inder 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 back-

lash 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 analy-
sis.
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.
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 gas-
ket.
114 SERIES 13-31

If gear housing (4) is not replaced, do not remove

timing pin assembly (2). For details of the proce-
dure for replacing the timing pin assembly, see
OVERALL ASSEMBLY OF ENGINE in this sec-
tion.
REMOVAL OF CARBON ACCUMULATED ON

CYLINDER LINER
Caution: When removing the carbon from the cylin-
der liner and cylinder head mounting sur-
face 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 proce-

dure, 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 pis-
ton 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 equiv-
alent fine fiber polishing pad and remove the remain-
ing 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 cylin-

der.
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 sur-
face 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 cylin-
der bore.
Be careful not to damage the crankshaft journal.
To prevent damage, set the connecting rod and pis-

ton assembly on a rack.
Caution: When using again, to make the worn mat-
ing surface match properly, install the pis-
ton and connecting rod assembly in the
cylinder with the same number (the cylin-
der 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.
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 cyl-
inder 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.

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 bear-
ing cap.
Mark the number of the journal that was removed
from the main bearing on the flat surface of the pro-
truding 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
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 equip-
ment can be used.
Universal liner puller (Part No. 3376051) with exten-
sion 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 cyl-
inder 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 clock-
wise 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 diame-
ter of the cylinder liner.
Insert the cylinder liner puller from the top of the cyl-
inder 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 clock-
wise 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 cylin-

der 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.
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 DISASSEMBLY AND ASSEMBLY
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 cyl-
inder 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.
Tightening
Bolt position Bolt size
torque value
A M8 24 Nm {2.4kgm}
B, C M10 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 counter-
bore, 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

DISASSEMBLY AND ASSEMBLY ASSEMBLY OF ENGINE
When reusing the cylinder liner, install the cylin-

der 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.
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.
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 cylin-
der 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

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

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.

If the cylinder liner exceeds the limit by
even a small amount, and another new cyl-
inder liner is installed to the bore which
exceeds the limit, the total of the tolerance
limit may bring the protrusion of the cylin-
der liner within the permitted range.
If the protrusion of the cylinder liner cannot fulfill

the specified conditions, machine the counter-
bore of the cylinder block liner, add a counter-
bore 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 cas-
ing.
Limit for clearance between cylinder liner and
block
mm
Min. 0.229
114 SERIES 13-43

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.

Measure the cylinder liner bore at points , , ,

, and to check the difference from the round-
ness. 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

If the difference from the roundness of the cylin-

der liner bore exceeds 0.08 mm,
Remove the cylinder liner so that it is possi-
ble to measure the cylinder block liner bore.
INSTALLATION OF TAPPET
Caution: Install the tappet as follows.
When reusing the camshaft and tappet, the tap-
pet must conform with the companion rope of
the camshaft. If no mark was made on the tap-
pet 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 cam-
shaft, 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

1/2 inch center punch

Install the piston cooling nozzle so that it is level with
the bearing saddle surface or below it.
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.
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.
With the main bearing, it is possible to use a crank-
shaft machined to 1 mm undersize from the origi-
nal diameter. For the connecting rod and main
bearing journal, the crankshaft machined to under-
size 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

Caution: Bearing protrusion portion must fit in

groove of the bearing saddle to ensure
that the bearing is correctly positioned and
to prevent damage to the engine.
Install the upper bearing.
When installing used bearings, install them to
the original position on the engine. When disas-
sembling, it is necessary to mark the main bear-
ing journal No. on the protruding portion of the
bearing.
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 lubri-
cant. If the lubricant is dirty, there will be
premature wear of the main bearing.
114 SERIES 13-47

INSTALLATION OF CRANKSHAFT
Use a cloth which does not leave threads. Clean the
crankshaft bearing journal.

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

INSTALLATION OF MAIN BEARING (LOWER)

Align protrusion with groove of the main bear-
ing 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 num-
bers 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 bear-

ing 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

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.
Check that the centers of the main bearing and
cap are aligned.
After pushing into the specified position, it is possi-
ble to tighten the mounting bolts of the main bearing
cap by hand.
19 mm
Tighten the main bearing cap mounting bolts uni-
formly in the order - given in the diagram.
When tightening the mounting bolts, tighten as fol-
lows.
Step Torque
1 50 Nm {5.1 kgm}
2 119 Nm {12.1 kgm}
3 176 Nm {17.9 kgm}
After the main bearing is tightened, the crank-

shaft 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

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 crank-
shaft counterweight.
Push the crankshaft towards the rear of the cyl-
inder block.
Align the dial indicator to 0.

Push the crankshaft towards the front of the cyl-
inder 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 cyl-
inder 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

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 crank-
shaft counterweight is marked on the crankshaft.
If there is a mark on the crankshaft counter-
weight, 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

INSTALLATION OF PISTON PIN

Coat the connecting rod piston pin hole and the pis-
ton 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

There is no need to heat the piston when install-
ing the piston pin. However, for this operation, it
is necessary to keep the piston at room temper-
ature or above.
Seat the retainer ring completely inside the pis-
ton 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 connect-
ing 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.
If the engine is rotated more than 90, the tappet
will fall out.
114 SERIES 13-53

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 follow-
ing 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
The piston ring in gap increases by 0.09 mm for

every increase of 0.03 mm in the wear of the cyl-
inder 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 distin-
guished by the TOP mark, dot, or other distinguish-
ing mark used by the manufacturer.
Assemble so that the TOP mark or other distinguish-
ing mark is facing up.
With the oil ring, either surface can be set facing up.
13-54 114 SERIES

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.

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

Install the top ring.
INSTALLATION OF PISTON ASSEMBLY

Install the connecting rod bearing to both the con-
necting rod and connecting rod cap.
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.
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 pre-
mature wear of the connecting rod bear-
ing.
Coat the connecting rod bearing with Lubriplate 105

so that a thin film forms.
Coat the piston ring and piston skirt with clean 15W-
40 engine oil.
13-56 114 SERIES

Position the piston rings.

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

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 direc-
tion 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.
If the piston does not move freely, remove the
piston and check that the piston ring is not bro-
ken 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

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 install-
ing 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 connect-
ing 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

19 mm socket, torque wrench

Tighten the connecting rod cap nuts.
Tighten the two mounting bolts in turn.
Step Torque
1 40 Nm {4.1 kgm}
2 80 Nm {8.2 kgm}
3 120 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 bear-
ing and the bearing size.
13-60 114 SERIES

INSTALLATION OH GEAR HOUSING

If they have been removed, install the 2 gear hous-
ing dowel pins.
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 injec-
tion 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

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 sec-
tion.
Install the gear housing and mounting bolts.
3 Mounting bolt:
M8: 24 Nm {2.4 kgm}

M12: 60 Nm {6.1 kgm}
Using the oil pan rail, trim the gear housing gasket
uniformly.
Be careful not to let the trimmed portion of the gas-
ket fall inside the engine.
INSTALLATION OF OIL PUMP

Coat the oil pump with clean 15W-40 engine oil.
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

Seat the oil pump back plate at the bottom of the cyl-
inder 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 - in the
order shown in the diagram.
Tighten the mounting bolts as follows.
Step Torque
1 5 Nm {0.51 kgm}
2 24 Nm {2.5 kgm}
Use the dial gauge on the magnet base to measure

the backlash of the idler gear.
Measure the backlash of the gear.

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

INSTALLATION OF CAMSHAFT
Coat the camshaft bore with Lubriplate 105.
For details of the installation of the camshaft
bushing, see REBUILDING AND REPLACING,
Installation of camshaft bushing.
When installing the crankshaft at the bot-
tom dead center (B, C, D) of the No. 1 cyl-
inder, 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 cylin-

der block up to the final journal.
Align the timing mark on the camshaft with the tim-

ing mark on the crankshaft.
13-64 114 SERIES

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

The end clearance is determined by the thick-
ness 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

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.
The mounting bolt at the 7 o'clock position is
longer, and it is also used to tighten the alterna-
tor mounting bracket.
INSTALLATION OF OIL SUCTION TUBE

Position the new oil suction tube gasket on the cylin-
der 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 Position Torque
1 Suction tube and block A 9 Nm {0.9 kgm}
2 Brace and block B 9 Nm {0.9 kgm}
3 Brace and suction tube C 9 Nm {0.9 kgm}
INSTALLATION OF REAR CRANKSHAFT SEAL

Use a special cloth to remove the rust and accumu-
lated dirt on the crankshaft flange.
Use a clean cloth to clean the rear crankshaft flange.
13-66 114 SERIES

Check visually that there is no wear in the seal con-

tact area.
If there is any deep groove in the seal contact area
with a depth similar to scratch marks made by finger-
nails 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 crank-
shaft 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.
Because of the equipment, crankshaft rear oil
seal (A) and wear sleeve (B) are combined into a
replacement kit and are installed to the crank-
shaft as an assembly. Do not remove the crank-
shaft rear oil seal from the wear sleeve of the
crankshaft rear seal.
Install the rear cover and the gasket.

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.
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

To lubricate the oil seal when installing, it is nec-

essary 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 con-
tacts the tip of the crankshaft.
Do not tighten any nut more than 1/2 turns in

order to prevent the wear sleeve from tightening
and having irregular elongation.
3 Nut: 20 Nm {2.0 kgm}
Remove the installation tool and threaded stud.
13-68 114 SERIES

To lubricate the oil seal when installing, it is nec-

essary 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.
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 crank-
shaft 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

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.
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.
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

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 posi-
tioned 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 origi-
nal 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

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 direc-

tion 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

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 rota-
tion until the pointer is aligned with the top dead cen-
ter (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

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 tight-

ened, 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 rotat-
ing 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 cyl-
inder block.
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

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 hous-

ing with the alignment dowel and the guide pin.
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 can-
not be read accurately. Align the dial gauge with the
6 o'clock position and set the gauge indicator to 0.
114 SERIES 13-75

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.
Do not apply force to the crankshaft until it exceeds
the bearing clearance. Do not put a lever in con-
tact 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 hori-
zontal 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 hori-
zontal" 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 ver-
tical" calculated from the example above are used,
the intersection is inside the range of the shaded
area. Therefore, the coaxiality of the flywheel hous-
ing is within the specified range.
13-76 114 SERIES

If the intersection is not within the range of the

shaded area, remove the dowel pin and install the
housing again.
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 hous-
ing 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 seal-

ant, then install in the hole at the bottom of the fly-
wheel housing.
Tighten the drain plug.
If the plug size is different, see the pipe tightening
torque in the Foreword.
114 SERIES 13-77

Install the plastic plug in the tachometer drive

access hole.
13 mm
Install the access plate and new access plate gas-
ket.
Install the access plate mounting bolts and tighten.
Clean the flywheel housing and cylinder block mount-

ing surfaces completely. Wash these surfaces. There
must be no oil or accumulated dirt on them.
The center bolt hole on the flywheel housing mount-

ing 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

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
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 bear-

ing.
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

Remove 2 guide pins (M12 x 1.25 x 90mm) at a 180

interval and install to the crankshaft flange.
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.
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

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 equiva-
lent and dial gauge attachment (Part No. ST-
1325), check the runout of flywheel bore and sur-
face .
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).
The total indicator reading (TIR) of the dial gauge
must not exceed 0.20 mm.
If the TIR exceeds the standard range, do as fol-

lows.
Remove the flywheel.
114 SERIES 13-81


flywheel mounting surface.

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

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 .
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.
Each time you measure the point, push the fly-
wheel 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 Max. flywheel
radius (A) surface TIR
mm mm
203 0.203
254 0.254
305 0.305
356 0.356
406 0.406
If the face runout of the flywheel is not within the stan-

dard 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

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 cylin-
der block.
Assemble the guide pin cooler gasket, oil cooler, and
oil cooler cover gasket.
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 fil-
ter head.
13-84 114 SERIES

INSTALLATION OF OIL FILTER

Before installing the oil filter, coat the gasket seal
surface with clean 15W-40 engine oil.
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.
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.
Check that the gasket is properly aligned with
the cylinder block holes.
Position the gasket with dowels.

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 cylin-
der block. Check that the cylinder head is installed
to the dowels inside the cylinder block.
114 SERIES 13-85

Coat the thread of the cylinder head mounting bolts

and the bottom of the head flange with clean 15W-
40 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.

There are six mounting bolts installed around the
injector hole.
The cylinder head mounting bolts can be distin-

guished 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

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 dia-
gram 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

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 correspond-
ing 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

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

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 dia-
gram.
13-90 114 SERIES

Compress the wave-shaped spring washer and install

it to the bottom half of the stand as shown in the dia-
gram.
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.
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

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 posi-
tioned 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}
ADJUSTING VALVE CLEARANCE

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 cen-
ter (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

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 clear-
ance 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 fly-

wheel. Rotate the crankshaft 360.
Always remove the timing pin.
114 SERIES 13-93

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 dia-
gram.
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.
For engine is equipped with a Westgate turbo-
charger, a stud bolt must be installed in the 3rd
hole from the front. This is for the Westgate actua-
tor hose clamp.
15 mm
Install the valve cover mounting bolts and tighten in
the order - as shown in the diagram.
13-94 114 SERIES

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 com-
pound.
Assemble the injector, seal sleeve, new copper seal
washer, and lock clamp.
Use only one washer.
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

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.
3 Mounting bolt:
Filter head I-joint :15 Nm {1.5 kgm}

Injector I-joint :9 Nm {0.9 kgm}
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.
INSTALLATION OF INTAKE MANIFOLD COVER

Install the manifold cover and the gasket. Do not
install the bolts in the holes used to secure the high-
pressure fuel line support bracket.
13-96 114 SERIES

INSTALLATON OF AFTERCOOLER
If the machine is equipped with an aftercooler, install
the aftercooler, gasket, and mounting bolts.
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.
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

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 nickel-
based 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
The turbocharger center bearing and compres-
sor outlet port must be installed facing in the cor-
rect 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

INSTALLATION OF TURBOCHARGER OIL

DRAIN TUBE
Coat the area around the end of the flange and bot-
tom 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.
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 tur-
bocharger.
Position the turbocharger drain hose, connect to the

drain tube, then tighten the clamps.
3 Clamp: 5 Nm {0.5 kgm}
13 mm, punch, hammer

If they are loose, tighten the turbine housing mount-
ing bolts. Then bend the lock plate to a flat surface
to prevent it from coming loose.
114 SERIES 13-99

7/16 inch, 10 mm
If necessary loosen the V-band clamp of the com-
pressor housing, and align the housing with the cen-
ter of the air crossover tube.
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 turbo-
charger.
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 fit-
ting at the top of the turbocharger and rotate the tur-
bocharger impeller to send oil to the bearing.
13-100 114 SERIES

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 bear-
ing housing and oil filter head, then tighten the joint.
3 Joint bolt: 24 Nm {2.4 kgm}
Install the oil supply line.

INSTALLATION OF TURBOCHARGER
EXHAUST OUTLET PORT CONNECTOR
Install the exhaust outlet port connector.
Do not tighten the 2 mounting bolts until the
band clamp is tightened.
3 Band clamp : 8 Nm {0.8 kgm}
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

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 direc-
tion so that the valve hole is at the 12 o'clock position.
3 Joint: 8 Nm {0.8 kgm}

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


TUBE
7/16 inch
Coat the thread with Teflon, then install the coolant
air bleed tube. Tighten the joint.
INSTALLATION OF COOLANT INLET CON-

NECTOR
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.
Set the alternator on the bracket, and secure with
the mounting bolts and spacers.
Do not tighten at this point.
114 SERIES 13-103

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 alter-
nator. Tighten the mounting bolts by hand.
Tighten the water pump mounting bolts.

15mm, 18mm, 19mm

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

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 lift-
ing equipment must be designed so that it
can lift the engine safely. The dry weight
of the engine plant with standard accesso-
ries 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

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 dia-
gram.
Engine crankshaft rotation tool (Part No. 3377371)

Check that the No. 1 cylinder is at top dead center
(T.D.C).
Rotate the crankshaft to match the direction of
rotation of the engine.
13-106 114 SERIES

In the fuel injection pump, timing pin , which deter-

mines 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 .
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

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.
Before installing the gear, clean the inside diam-
eter of the fuel injection pump drive gear and the
outside diameter of the shaft, and dry them.
The O-ring of the oil supply orifice on the Bosch
PES.P fuel injection pump is inside the gear
housing.
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

15 mm and 13 mm, fuel injection pump mounting

tool kit (Part No. 3823956)
Install the mounting nut.
3 Mounting nut: 44 Nm {4.5 kgm)
Rear support bracket:
3 Mounting bolt for M8 pump bracket:
24 Nm {2.4 kgm}
3 Mounting bolt for M10 block and bracket:
45 Nm {4.6 kgm}
Top support bracket: 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

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.
RSV: 450ml
RQV: 750ml
RQVK: 750ml
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.
When checking the backlash, if the neighboring
gears are not prevented from moving, the read-
ing 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

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

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 Injec-
tion Pump)
10 and 19 mm (PES6P Fuel Injection Pump)
Loosen the vibration isolator capscrews so the fuel
lines can be easily moved.
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 con-
necting 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 com-
ponent.
Install the lines in the reverse order of removal.
efore installing the fuel injection pipe to the injec-

tor of fuel injection pump, clean the high-pres-
sure 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:

24 Nm {2.4 kgm}
3 Anti-vibration clamp bolt: 6 Nm {0.6 kgm}
13-112 114 SERIES

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 posi-
tion 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 fac-
ing 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
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.
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 appropri-
ate parts catalog for the 114 Series.
114 SERIES 13-113

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
Part name Q'ty
number
Driver 1
Spacer 2
M14 x 1.5 x 60 mm 2
Cotter pin 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 with the wear

sleeve.
13-114 114 SERIES

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

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 com-
pletely.
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.
10mm
Tighten the mounting bolts of the gear cover.
Remove the seal pilot tool from the nose of the
crankshaft.
13-116 114 SERIES

When using, install the crankshaft oil seal dust seal

as follows.
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.
Using the engine crankshaft rotation tool, make sure

that the engine cannot rotate.
Install the fan hub pulley, then secure with the mount-
ing bolt.
If the belt has already been installed, it is easier
to tighten the mounting bolts.
114 SERIES 13-117

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 ten-
sioner while sliding the belt over the water
pump pulley.
13 mm
Tighten the fan hub pulley mounting bolts.
INSTALLATION OF ENGINE FRONT SUP-

PORT
15 mm
Install the engine front support. Tighten the mount-
ing 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

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

Using a bolt of a length of 30 mm, install air com-

pressor 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 tighten-
ing torque.
9/16 inch
Install the oil supply line.
3 Flange nut: 8 Nm {0.8 kgm}
15/16 inch
Caution: When using rubber grommets for the cool-
ing system, to prevent leakage of the cool-
ant, 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.

Mounting bolt:
3 Inlet port flange nut: 65 Nm {6.6 kgm}
3 Outlet port flange nut: 24 Nm {2.4 kgm}

(compressor cylinder head joint: 1/2 NPT)
13-120 114 SERIES

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
REPAIR AND REPLACEMENT OF PARTS
15 REPAIR AND REPLACEMENT

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

OUTLINE REPAIR AND REPLACEMENT OF PARTS
OUTLINE
REPAIR GUIDE LINE FOLLOW WASHING METHODS GIVEN IN
Since the latest diesel technologies are applied to MANUAL
the 114 Series engines, it is required to perform the When repairs have been completed, check that all
conventional repair works at a high quality level for mental particles produced by the machining have
those engines. As a part of support to the mainte- been completely removed and that the applicable
nance of the 114 Series engines, new spare parts parts have been completely cleaned.
are available in every part of the world.
FOLLOW INSPECTION METHODS GIVEN IN

WHEN SHOULD SUBSTITUTE REPAIRS BE MANUAL
CARRIED OUT
After completing repairs, carry out the necessary
In the following explanation of the procedures, men- inspections to check that the applicable parts fulfill
tion is also made of a separate repair method to use the technological requirements needed to withstand
instead of large-scale replacement of engine parts. future continued use as an engine component.
The decision is governed by various conditions,
such as technical demands, possibility of use, cost,
and consideratoins related to the length of the down-
time of the equipment.
INSPECTION
This procedure manual assumed that the compo-
nent parts have already been checked, and that the
points which do not match the standard have been
checked during repair or overhaul. This manual cov-
ers 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 rec-
ommendations 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
REPAIR AND REPLACEMENT OF PARTS 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 spe-
cial 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 REPAIR AND REPLACEMENT OF PARTS
METHOD FOR USING TAPER

THREAD PLUGS TO SEAL
POCKETS AND SMALL
HOLES IN CASTINGS
This explanation of the repair procedure is a guide-
line for the method of use of a taper thread plug to
repair slight defects which cause leakage in cast-
ings, 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 cast-

ings in the following cases.
1. Defects which can be removed with a tap drill.
2. Places where the necessary plug size is a maxi-
mum of 27.53 mm (1.084 in).
3. Places with defects where the maximum thick-
ness 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

REPAIR AND REPLACEMENT OF PARTS POCKETS AND SMALL HOLES IN CASTINGS
X Y
Cummins
Ironite Diameter at Thread Drill Ironite
tap
Part No. small end length size tap No.
Part No.
mm mm
210200 5.08 3.8 11/64 530200 555228
210235 5.97 23.8 13/64 530235 555229
210237 8.32 36.5 5/16 530237 555230
210420 10.67 25.4 25/64 530420 555231
210421 10.67 36.5 25/64 530420 555232
210490 12.45 25.4 15/32 530490 555234
210491 12.45 36.5 15/32 530590 555234
210590 14.99 25.4 23/32 530780 555236
260780 19.81 25.4 23/32 530780 555236
261080 27.53 25.4 1.00 531080 555237
A: Standard pipe plug

B: Taper threaded plug
1. Using a portable disc grinder or wire brush, The thickness of the wall of the casting at the
removed all paint and rust from the defective problem point must be at least 3.97 mm
area. 4. Use the correct size of taper to cut the thread in
Caution: If repair is carried out with the engine still the hole. A minimum of at least four complete
installed to the machine, be careful not to threads is necessary to seal the plug. Be sure to
let any chips or particles enter the engine. remove all chips and particles after grinding.
2. Make a hole with the correct size of tap drill to 5. Coat the plug thread with Loctite 601 ST-
match the plug that is used. Make sure that the 1272-12 Loctite compound or the equivalent.
size of the drill bit is large enough to completely 6. Insert the plug and tighten it.
remove the problem area. Do not use a drill bit 7. Using a metal saw, cut off the plug. Leave at
that is larger than necessary. After making the least 0.794 mm of the plug from the surface.
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
114 SERIES 15-5

POCKETS AND SMALL HOLES IN CASTINGS REPAIR AND REPLACEMENT OF PARTS
8. Using a small ball peen hammer flatten the pro-

truding 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 pres-
sure of 343 kPa {3.5 kg/cm2}. Apply pres-
sure 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
REPAIR AND REPLACEMENT OF PARTS WORN BY LARGE SIZE COPPER PLATED PLUGS
METHOD FOR REPAIRING

TAPER THREAD PLUG HOLES
WORN BY LARGE SIZE COP-
PER 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 REPAIR AND REPLACEMENT OF PARTS
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 limita-
tion 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

REPAIR AND REPLACEMENT OF PARTS INSPECTION FOR REUSE OF CYLINDER BLOCK
INSPECTION FOR REUSE OF

CYLINDER BLOCK
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 cyl-
inder.
Cylinder Block Flatness Specification
mm
End-to-End 0.075
Side-to-Side 0.075
Caution: Do not proceed with the repair if the cylin-

der block head deck is damaged or not
flat. The engine will have to be removed
for resurfacing the block.
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 clear-
ance 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

INSPECTION FOR REUSE OF CYLINDER BLOCK REPAIR AND REPLACEMENT OF PARTS
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.
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 installa-
tion 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

REPAIR AND REPLACEMENT OF PARTS INSPECTION FOR REUSE OF CYLINDER BLOCK
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

mm
With new bearings installed: Min. 98.079
Max. 98.125
Without bearings Min. 104.982
Max. 105.018
The radial runout must not exceed 0.0127 mm.
114 SERIES 15-11

INSPECTION FOR REUSE OF CYLINDER BLOCK REPAIR AND REPLACEMENT OF PARTS
Check the camshaft holes for a scratch and exces-

sive 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

REPAIR AND REPLACEMENT OF PARTS INSTALLATION OF EXPANSION PLUGS
INSTALLATION OF EXPAN-
SION 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.
Install each expansion plug to the correct depth
with an expansion plug driver.
Use the following expansion plug drives.
Part No. of Dimension of
Part No. of tool expansion expansion
plug plug (in.)
3822372 3900955 0.375
3823521 3902606 0.8125
3376816 3900957 1.00
3823522 156075 1.1875
3823523 3905401 1.375
3823524 3900965 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 fol-
lowing table.
114 SERIES 15-13

INSTALLATION OF EXPANSION PLUGS REPAIR AND REPLACEMENT OF PARTS
Tighten each pipe plug to proper torque.

Torque for pipe plug
Size Torque Torque
Thread Outside Aluminum parts Cast steel or
diameter of plug cast iron parts
in mm Nm {kgm} Nm {kgm}
1/16 8.1 5 {0.5} 15 {1.5}
1/8 10.4 15 {1.5} 20 {2.0}
1/4 13.7 20 {2.0} 25 {2.5}
3/8 17.3 25 {2.5} 35 {3.7}
1/2 21.6 35 {3.7} 55 {5.6}
3/4 26.7 45 {4.6} 75 {7.6}
1 33.5 60 {6.1} 95 {9.7}
11/4 42.2 75 {7.6} 115 {11.7}
11/2 48.3 85 {8.7} 135 {13.8}
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
(5.) 1/2 inch pipe plug
Pipe plugs and expansion plugs on right side of cyl-

inder block
(1.) 2.287 inch inch expansion 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
(3.) Expansion plug of camshaft hole
15-14 114 SERIES

REPAIR AND REPLACEMENT OF PARTS INSTALLATION OF EXPANSION PLUGS
Pipe plugs and expansion plugs on left side of cylin-

der block
(1.) 1-3/8 inch expansion plug on oil filler side
(4.) 3/8 inch expansion plug or level gauge tube
114 SERIES 15-15

INSTALLATION OF EXPANSION PLUG TO CAMSHAFT
HOLE REPAIR AND REPLACEMENT OF PARTS
INSTALLATION OF EXPAN-
SION 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 ham-

mer.
Expand the expansion plug until its projected part is

lower than the cylinder block surface.
15-16 114 SERIES

REPAIR AND REPLACEMENT OF PARTS REMOVAL OF CAMSHAFT BUSHING
REMOVAL OF CAMSHAFT
BUSHING
Tool (3823509) to remove and fit camshaft bush-
ing
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 REPAIR AND REPLACEMENT OF PARTS
INSTALLATION OF CAMSHAFT BUSHING

1. Make match marks (1) at the smaller one of the
2 oil holes of the camshaft bushing and the oil
hole on the lower side of camshaft bore of the
cylinder block with a marker.
a Use the matchmarks to align the bushing
and bore when installing.
a In the journals at the front and rear ends, the
lower oil hole of the camshaft bushing is
aligned with that of the cylinder block.
a In the journals at the front and rear ends, the
upper oil hole of the camshaft bushing is not
aligned with that of the cylinder block, but
this is not a problem.
In other journals, the upper and lower oil
holes of the camshaft bushing are aligned
with those of the cylinder block.
2. Slide and install the camshaft bushing to the

camshaft bushing remover.
a Install the camshaft bushing so that cutout
(a) on its end face is on the rear side of the
engine.
3. Align match marks (1) of the camshaft bushing

and cylinder block, and drive the front camshaft
bushing to the correct installation depth.
a When the camshaft bushing is installed to a
proper depth, its oil hole aligns with that of
the cylinder block.
a After installing, check that a rod 3.2 mm in

diameter can be inserted into the oil holes
4. Install the remaining camshaft bushings. Work

on from the rear side of the cylinder block to the
front side.
5. Remove the drive bar, camshaft bushing

remover, and guide from the cylinder block.
15-18 114 SERIES

(7)
REPAIR AND REPLACEMENT OF PARTS INSTALLATION OF CAMSHAFT BUSHING
Measure the inside diameter of the installed cam-

shaft bushing.
Inside diameter of camshaft bushing
(after installed)
mm
Min. 60.058
Max. 60.112
114 SERIES 15-18-1

(7)
CLEANING AND INSPECTION OF CYLINDER LINERS
REPAIR AND REPLACEMENT OF PARTS BEFORE REUSING THEM
CLEANING AND INSPECTION

OF CYLINDER LINERS
BEFORE REUSING THEM
CREANING OF CYLINDER LINERS
Caution: Do not use any abrasives in the ring travel
area of the liner. The liner can be dam-
aged.
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 pro-

tective 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 diame-

ter 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

BEFORE REUSING THEM REPAIR AND REPLACEMENT OF PARTS
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.
Pits must not be more than 1.6 mm [0.06inch]
deep.
Replace the liner if the pits are too deep or if the cor-
rosion cannot be removed with fine emery cloth.
Inspect the inside diameters for vertical scratches

deep enough to be felt with a fingernail.
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 origi-
nal 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 per-
cent) 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.
mm
Min. 114.000
Max. 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 REPAIR AND REPLACEMENT OF PARTS

OF PISTON BEFORE REUS-
ING IT
REMOVE THE PISTON RINGS
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.
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 pro-

tective 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

REPAIR AND REPLACEMENT OF PARTS REUSING IT
INSPECTION OF PISTONS
Inspect the piston for damage and excessive wear.
Check the top ring grooves, skirt and pin bore.
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 , pin bore and

skirt for cracks or damage.
Do not use pistons with cracks.
Measure the piston pin hole when the piston temper-

ature is 20C.
Piston pin hole I.D.
mm
Min. 45.006
Max. 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.
mm
Min. 44.993
Max. 45.003
Measure the piston skirt diameter as illustrated.

Piston skirt O.D.
mm
Min. 113.814
Max. 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, pis-
ton 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

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.
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
Clearance of bearing: Subtract the crankshaft jour-
nal diameter from the inside diameter of the con-
necting 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
Clearance of bearing: Subtract the crankshaft jour-

nal diameter from the inside diameter of the con-
necting rod after the bearing is fitted.
Max. clearance of bearing: 0.134 mm
15-26 114 SERIES

Main journal of crankshaft

mm
Circularity Max. 0.050
Taper Max. 0.013
The following oversized main bearing and thrust

bearing can be used for a crankshaft machined to an
under-size.
Size of thrust bearing
Oversize 0.000 0.25mm 0.50mm
Journal 0.000 x x x
Outside
0.25mm x x
diameter
0.50mm x x
0.75mm x
1.00mm x
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

REPAIR AND REPLACEMENT OF PARTS REPLACEMENT OF CRANKSHAFT GEAR
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.

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

REPLACEMENT OF CRANKSHAFT GEAR REPAIR AND REPLACEMENT OF PARTS
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 jour-

nal.
Outside diameter of crankshaft journal
mm
Min. 75.987
Max. 76.006
INSTALLATION OF CRANKSHAFT GEAR

Drive the gear positioning dowel pin in the crank-
shaft with a soft hammer.
The pin must be projected by 1.02 mm from the
crankshaft surface.
15-30 114 SERIES

REPAIR AND REPLACEMENT OF PARTS REPLACEMENT OF CRANKSHAFT GEAR
Caution: Do not exceed the specified time or tem-

perature when heating the crankshaft gear.
The gear and teeth can be damaged.
Heat the Gear in an oven for a minimum of 45 min-
utes 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.
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 REPAIR AND REPLACEMENT OF PARTS

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 follow-
ing 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

CLEANING AND INSPECTION OF MAIN BEARINGS BEFORE
REPAIR AND REPLACEMENT OF PARTS REUSING THEM
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 bear-

ing combinations are available for crankshafts that
have been machined undersize, either on the main
journal or thrust bearing face:
Size of thrust bearing
Oversize 0.000 0.25mm 0.50mm
Journal 0.000 x x x
Outside
0.25mm x x
diameter
0.50mm x x
0.75mm x
1.00mm x
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 REPAIR AND REPLACEMENT OF PARTS

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
REPAIR AND REPLACEMENT OF PARTS BEARINGS BEFORE REUSING THEM

OF CONNECTING ROD BEAR-
INGS BEFORE REUSING
THEM
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 follow-
ing defects.
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 break-

age and burrs.
If the burrs of a bearing cannot be removed with fine
iron oxide and cloth, replace the bearing.
114 SERIES 15-35

CLEANING AND INSPECTION OF CONNECTING ROD
BEARINGS BEFORE REUSING THEM REPAIR AND REPLACEMENT OF PARTS
Measure the rod bearing shell thickness with an out-

side 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 ser-
vice 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

OF CONNECTING RODS
BEFORE REUSING THEM
CLEANING OF CONNECTING RODS
Each set of a connecting rod cap and a connect-
ing 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 protec-

tive clothing and safety glasses or a face
shield. Hot steam can cause serious per-
sonal 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

BEFORE REUSING THEM REPAIR AND REPLACEMENT OF PARTS
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
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.
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 spec-
ified 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 REPAIR AND REPLACEMENT OF PARTS
INSPECTION OF CONNECT-
ING 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.
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.
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.
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 man-
drel of the piston pin hole by moving the dial holder.
Tighten the bracket to hold the dial indicator in posi-
tion.
Set the dial indicator and read the zero point.
Turn the rod horizontally by 180 and set the con-
necting rod in the fixing tool again.
15-40 114 SERIES

INSPECTION OF CONNECTING RODS FOR BEND
REPAIR AND REPLACEMENT OF PARTS AND TORSION
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 CON-

NECTING 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 con-

necting 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
mm
When bushing is removed Max. 0.50
When bushing is fitted Max. 0.30
114 SERIES 15-41

REPLACEMENT OF CONNECTING ROD BUSHINGS REPAIR AND REPLACEMENT OF PARTS
REPLACEMENT OF CON-
NECTING ROD BUSHINGS
Part No.3823690, Connecting Rod Pin Bore Bush-
ing Removal/Installation Tool
This tool used to remove and install the bushing to
the correct position.
Ref.No. Part No. Description Qty
(1) 3823691 Anvil 1
(2) 3823693 Cup 1
(3) 3823692 Mandrel 1
(4) 3823694 Driver Ring (Thick) 1
(5) 3823695 Knock-out-ring (Thinner) 1
(6) Cotter Pin 1
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 cot-

ter pin.
15-42 114 SERIES

REPAIR AND REPLACEMENT OF PARTS REPLACEMENT OF CONNECTING ROD BUSHINGS
Install the mandrel in the base. Place the connect-

ing 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 diame-

ter of the connecting rod bushing.
If the inside diameter of the connecting rod bush-
ing is out of the specified range, replace the con-
necting 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 man-
drel.
Install the cap and secure it with the cotter pin.
15-44 114 SERIES

REPAIR AND REPLACEMENT OF PARTS REPLACEMENT OF CONNECTING ROD BUSHINGS
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.
Any connecting rod is not chamfered double. It
may be chamfered additionally so that the bush-
ing can be installed easily. Do not chamfer the
part in the bushing which is not supported, how-
ever.
Matching the oil hole in the bushing to the connect-

ing rod (by using the groove in the mandrel), push
the bushing in the pin hole of the rod until the man-
drel 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.
Do not use a honing machine of floating rod
type.
INSPECTION
After each connecting rod is machined, all of its
limit dimensions must be checked.
15-46 114 SERIES

REPAIR AND REPLACEMENT OF PARTS REPLACEMENT OF VALVE INSERTS OF CYLINDER HEAD
REPLACEMENT OF VALVE
INSERTS OF CYLINDER HEAD
REMOVAL
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 cylin-
der head, it can cause a serious damage.
114 SERIES 15-47

REPLACEMENT OF VALVE INSERTS OF CYLINDER HEAD REPAIR AND REPLACEMENT OF PARTS
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 crack-
ing and damage.
If the hole is cracked or damaged, replace the cylin-
der 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
If either dimension does not satisfy the standard,

replace the cylinder head.
ASSEMBLY
Cool the new valve seat inserts at 0C for 30 min-
utes 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 cyl-
inder 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
The sealing face of the valve must be at the cen-

ter of the valve seat insert.
If the valve seat zone is worn more than the stan-
dard value, see Grinding of valve seat inserts or
Replacement of valve seat inserts of cylinder head.

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
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 Nominal
65.66
exhaust valve value
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
Nominal
Standard spring 37.90
value
Load C on valve spring at opening height (new)

N {kg}
Standard spring
Air intake valve and Min. 960 {97.89}
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
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 sur-
face and head.
Clean the valve and remove the all carbon from
it before grinding its sealing surface.
Grind the valve sealing surface with a valve face fin-

isher (Part No. 3376256).
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 thick-

ness of its head at its periphery.
Thickness of valve head (at periphery)
mm
Air intake valve Max. 3.01
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 for-
ward and backward 3 4 turns. If the seal face is in
contact with the valve seat normally, the marks on it
are broken.
If the valve and valve seat are machined accu-
rately, they do not need to be lapped with lapping
compound. If lapping is required, inspect the con-
ditions of the grinder and grindstone.
Install the all valves to the cylinder head. Perform

the vacuum test on the valve seats with a valve vac-
uum tester (Part No. ST-1257).
See Vacuum test on valve seats of cylinder head.
GRINDING OF VALVE SEAT INSERTS

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 and core pulling tool to

the valve guide.
Rotate the core to check that it is installed normally.
114 SERIES 15-55

Install valve seat grindstone on the grinder.

The size and angle of the grindstone must be cor-
rect. (Air intake valve: 30, Exhaust valve: 45).
Install the grinder on the core.
When the motor of the drive unit is installed, grind-
stone 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
If the concentricity of the valve seat does not sat-

isfy the specification, grind the valve seat again.
If the concentricity cannot satisfy the specifica-
tion, replace the valve seat insert. See Replace-
ment of valve seat inserts of cylinder head.
Install the adjusted valves to the respective holes.

Hold each valve on the valve seat insert side.

Measure the depth of the valve in the cylinder head.
Depth of valve from cylinder head
mm
Max. 1.62
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 lim-
its, 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, mea-
sure 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 pen-
cil.
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, align-
ing 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 grind-
stone 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 grind-
stone 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 out-
side of the expansion plugs.
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. Expansion plug No. Q'ty Location
3823522 156075 1 A
3823524 3900965 2 B
3823522 3032693 5 C
3376815 3912900 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
Location Size Nm {kgm}
(A) 1/16 inch NPT 8 {0.8}
(B) 1/4 inch NPT 12 {0.12}
(C) 1/2 inch NPT 24 {2.4}
(D) Hexagon plug 80 {8.0}
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.
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 assem-

blies on the valve stems.
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 com-

pressor (Part No. ST-448) or equivalent (See the ser-
vice tools list).
Install valve cotter pin for the valve spring retainer.
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 ham-
mer.
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 REPAIR AND REPLACEMENT OF PARTS
REPLACEMENT OF VALVE
GUIDES OF CYLINDER HEAD
DISASSEMBLY
The valve seats of the replaced valve guides must
be ground.
Remove used valve guide with valve guide driver
(Part No. 3823271).
Clean the inside of the valve guide hole of the cylin-

der head with a hard brush and dry it with com-
pressed 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

REPAIR AND REPLACEMENT OF PARTS REPLACEMENT OF VALVE GUIDES OF CYLINDER HEAD
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 fol-
lowing 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 microme-
ter.
Installing height of valve guide
mm
Max. 21.16
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

REPLACEMENT OF VALVE GUIDES OF CYLINDER HEAD REPAIR AND REPLACEMENT OF PARTS
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

REPAIR AND REPLACEMENT OF PARTS CYLINDER HEAD-PRESSURE TEST
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
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 fix-

ture plate. Apply air pressure.
Air Pressure: 276 kPa {27 kg/cm2}
Use a nylon lifting strap and a hoist to place the cyl-
inder 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

CYLINDER HEAD-PRESSURE TEST REPAIR AND REPLACEMENT OF PARTS
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

REPAIR AND REPLACEMENT OF PARTS VACUUM TEST ON VALVE SEATS OF CYLINDER HEAD
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).
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 cyl-
inder 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.
Set the seal around the valve of the cylinder head
without making clearance.
Turn switch ON.

Set vacuum control valve to the OPEN position.
If the vacuum gauge pointer moves clockwise, the
vacuum control valve is at the OPEN position.
114 SERIES 15-67

VACUUM TEST ON VALVE SEATS OF CYLINDER HEAD REPAIR AND REPLACEMENT OF PARTS
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

REPAIR AND REPLACEMENT OF PARTS CLEANING AND INSPECTION OF CYLINDER HEAD BOLTS

OF CYLINDER HEAD BOLTS
Caution: Protect the bolts from being damaged. Break-
age 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 fol-

lowing 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

CLEANING AND INSPECTION OF CYLINDER HEAD BOLTS REPAIR AND REPLACEMENT OF PARTS
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
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

Engine 114 - 2 Series Komatsu

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11 STRUCTURE AND FUNCTION,

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

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

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

00-2 114 SERIES

( ) Page to be deleted Discard

Pages having no marks are not revised at this time.

LIST OF REVISED PAGES

Revision Revision Revision Revision Revision

q 00- 1 (7) 01-35 (2) 11- 44 12- 6 12- 49

114 SERIES 00-2-1

12-305 13- 41 13-100 15- 37

00-2-2 114 SERIES

IMPORTANT SAFETY NOTICE

GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to keep

STRUCTURE AND FUNCTION

TESTING AND ADJUSTING

DISASSEMBLY AND ASSEMBLY

HOW TO READ THE SHOP MANUAL REVISED EDITION MARK

VOLUMES When a manual is revised, an edition mark

Chassis volume: Issued for every machine model REVISIONS

DISTRIBUTION AND UPDATING

Slinging near the edge of the hook may cause

If a part cannot be smoothly removed from the

The allowable load value is estimated to be one-

2) Sling wire ropes from the middle portion of the

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

k Before carrying out the following work, release Type 1

k Even if the residual pressure is released from

2) Hold adapter (1) and push hose joint (2) into

3) After hose joint (2) is pushed into adapter (3),

4) Hold hose adapter (1) or hose (5) and pull it out.

2) After inserting the hose in the mating adapter

Used to prevent rubber gaskets, rub-

Holtz Used as heat-resisting sealant for re-

Used as lubricant for sliding portion

SYG2-400CA Used for normal temperature, light

Molybdenum Used for heavy load portion

SUNSTAR Used as primer for cab side

"S" is used for high-tempera-

SUNSTAR Used to seal joints of glass

STANDARD TIGHTENING TORQUE

6 10 11.8 14.7 1.2 1.5

16 24 235 285 23.5 29.5

27 41 1150 1440 118 147

6 10 5.9 9.8 0.6 1.0

TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

Thread diameter Width across flat Tightening torque

14 19 24.5 4.9 2.5 0.5

TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

Thread diameter Width across flat Tightening torque

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

Thread diameter Width across flat Tightening torque (Nm {kgm})

02 14 35 63 {3.5 6.5} 44 {4.5}

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS

Thread diameter Width across flat Tightening torque (Nm {kgm})

08 08 14 5.88 8.82 {0.6 0.9} 7.35 {0.75}

TIGHTENING TORQUE FOR 102 ENGINE SERIES

ELECTRIC WIRE CODE

0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal

2 26 0.32 2.09 3.1 20 Lighting, signal etc.

5 65 0.32 5.23 4.6 37 Charging and signal