Shop Manual
HYDRAULICEXCAVATOR
ENGINE
6D114E-3
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Copyright2017Komatsu PrintedinU.S.A. KomatsuAmericaCorp. August2017
01INDEXANDFOREWORD.
10STRUCTURE,FUNCTIONANDMAINTENANCESTANDARD
20STANDARDVALUETABLES
30TESTINGANDADJUSTING.
40TROUBLESHOOTING.
50DISASSEMBLYANDASSEMBLY.
80APPENDIX.
90DIAGRAMSANDSCHEMATICS.
SAFETYNOTICE
IMPORTANTSAFETYNOTICE
Properserviceandrepairisextremelyimportantforthesafeoperationofyourmachine.Theserviceandrepair techniquesrecommendedanddescribedinthismanualarebotheffectiveandsafemethodsofoperation.Some oftheseoperationsrequiretheuseoftoolsspeciallydesignedforthatpurpose.
Topreventinjurytoworkers,thesymbolisusedtomarksafetyprecautionsinthismanual.Thecautions accompanyingthissymbolshouldalwaysbefollowedcarefully.Ifanydangeroussituationarisesormaypossibly arise,firstconsidersafety,andtakethenecessaryactionstodealwiththesituation.
GENERALPRECAUTIONS
Mistakesinoperationareextremelydangerous.Read theOPERATION&MAINTENANCEMANUALcarefully BEFOREoperatingthemachine.
1.Beforecarryingoutanygreasingorrepairs,read alltheprecautionsgivenonthedecalswhichare fixedtothemachine.
2.Whencarryingoutanyoperation,alwayswear safetyshoesandhelmet.Donotwearloosework clothes,orclotheswithbuttonsmissing. Alwayswearsafetyglasseswhenhittingpartswith ahammer. Alwayswearsafetyglasseswhengrindingparts withagrinder,etc.
3.Ifweldingrepairsareneeded,alwayshavea trained,experiencedweldercarryoutthework. Whencarryingoutweldingwork,alwayswear weldinggloves,apron,glasses,capandother clothessuitedforweldingwork..
WARNING!Nevermodify,weld,cut,ordrill onanypartofaROPS structure.Doingsomay weakenthestructurewhich couldleadtopossiblefailurein arolloversituation
4.Whencarryingoutanyoperationwithtwoormore workers,alwaysagreeontheoperatingprocedure beforestarting.Alwaysinformyourfellowworkers beforestartinganystepoftheoperation.Before startingwork,hangUNDERREPAIRsignsonthe controlsintheoperator'scompartment.
5.Keepalltoolsingoodconditionandlearnthecorrectwaytousethem.
6.Decideaplaceintherepairworkshoptokeeptools andremovedparts.Alwayskeepthetoolsand partsintheircorrectplaces.Alwayskeepthework areacleanandmakesurethatthereisnodirtoroil onthefloor.Smokeonlyintheareasprovidedfor smoking.Neversmokewhileworking.
PREPARATIONSFORWORK
1.Beforeaddingoilormakingrepairs,parkthe machineonhard,levelground,andblockthe wheelsortrackstopreventthemachinefrommoving.
2.Beforestartingwork,lowerblade,ripper,bucketor anyotherworkequipmenttotheground.Ifthisis not possible,insertthesafetypinoruseblockstopreventtheworkequipmentfromfalling.Inaddition, besuretolockallthecontrolleversandhang warningsignsonthem.
3.Whendisassemblingorassembling,supportthe machinewithblocks,jacksorstandsbeforestartingwork.
4.Removeallmudandoilfromthestepsorother placesusedtogetonandoffthemachine.Always usethehandrails,laddersorstepswhengettingon oroffthemachine.Neverjumponoroffthe machine.Ifitisimpossibletousethehandrails, laddersorsteps,useastandtoprovidesafefooting.
PRECAUTIONSDURINGWORK
1.Whenremovingtheoilfillercap,drainplugor hydraulicpressuremeasuringplugs,loosenthem slowlytopreventtheoilfromspurtingout.Before disconnectingorremovingcomponentsoftheoil, wateroraircircuits,firstremovethepressurecompletelyfromthecircuit.
2.Thewaterandoilinthecircuitsarehotwhenthe engineisstopped,sobecarefulnottogetburned. Waitfortheoilandwatertocoolbeforecarrying outanyworkontheoilorwatercircuits.
3.Beforestartingwork,removetheleadsfromthe battery.ALWAYSremovetheleadfromthenegative(-)terminalfirst.
4.Whenraisingheavycomponents,useahoistor crane.Checkthatthewirerope,chainsandhooks arefreefromdamage.Alwaysuseliftingequipmentwhichhasamplecapacity.Installthelifting equipmentatthecorrectplaces.Useahoistor craneandoperateslowlytopreventthecomponentfromhittinganyotherpart.Donotworkwith anypartstillraisedbythehoistorcrane.
5.Whenremovingcoverswhichareunderinternal pressureorunderpressurefromaspring,always leavetwoboltsin positiononoppositesides.Slowlyreleasethe pressure,thenslowlyloosentheboltstoremove.
6.Whenremovingcomponents,becarefulnotto breakordamagethewiring,Damagedwiringmay causeelectricalfires.
7.Whenremovingpiping,stopthefueloroilfrom spillingout.Ifanyfueloroildripsontothefloor, wipeitupimmediately.Fueloroilonthefloorcan causeyoutoslip,orcanevenstartfires.
8.Gasolineorotherfuelsshouldneverbeusedto cleanparts.Cleanpartwithappropriatesolvents.
9.Besuretoassembleallpartsagainintheiroriginal places.Replaceanydamagedpartwithnewparts.
•Wheninstallinghosesandwires,besurethat theywillnotbedamagedbycontactwithother partswhenthemachineisbeingoperated.
10.Wheninstallinghighpressurehoses,makesure thattheyarenottwisted.Damagedtubesaredangerous,sobeextremelycarefulwheninstalling tubesforhighpressurecircuits.Alsocheckthat connectingpartsarecorrectlyinstalled.
11.Whenassemblingorinstallingparts,alwaysuse thespecifiedtighteningtorques.Wheninstalling protectivepartssuchasguards,orpartswhich vibrateviolentlyorrotateathighspeed,beparticularlycarefultocheckthattheyareinstalled correctly.
12.Whenaligningtwoholes,neverinsertyourfingers orhand.Becarefulnottogetyourfingerscaughtin ahole.
13.Whenmeasuringhydraulicpressure,checkthat themeasuringtooliscorrectlyassembledbefore takingany measurements.
14.Takecarewhenremovingorinstallingthetracksof track-typemachines.Whenremovingthetrack,the trackseparatessuddenly,soneverletanyone standateitherendofthetrack.
15.Whenjumpstartingthemachine,onlyusea machineofsimilarsizeandvoltage.Neverusea arcwelderorotherelectricalgeneratingequipment tojumpstartthemachine.Carefullyreviewthe safetyandproceduresforjumpstartingthe machine.
Thisshopmanualhasbeenpreparedasanaidtoimprovethequalityofrepairsbygivingtheservicemananaccurate understandingoftheproductandbyshowinghimthecorrectwaytoperformrepairsandmakejudgments.Make sureyouunderstandthecontentsofthismanualanduseittofulleffectateveryopportunity.
Thisshopmanualmainlycontainsthenecessarytechnicalinformationforoperationsperformedinaserviceworkshop.Foreaseofunderstanding,themanualisdividedintothefollowingsections.Thesesectionsarefurther dividedintoeachmaingroupofcomponents.
GENERAL
Thissectionliststhegeneralmachinedimensions,performancespecifications,componentweights,andfuel, coolantandlubricantspecificationcharts.
STRUCTURE,FUNCTIONANDMAINTENANCESTANDARD
Thissectionexplainsthestructureandfunctionofeachcomponent.Itservesnotonlytogiveanunderstanding ofthestructure,butalsoservesasreferencematerialfortroubleshooting.Inaddition,thissectiongivesthe judgmentstandardswheninspectingdisassembledparts.
STANDARDVALUETABLE
Thissectionexplainsthestandardvaluesfornewmachineandjudgmentcriteriafortesting,adjustingand troubleshooting.Thisstandardvaluetableisusedtocheckthestandardvaluesintestingandadjustingandto judgepartsintroubleshooting.
TESTINGANDADJUSTING
Thissectionexplainscheckstobemadebeforeandafterperformingrepairs,aswellasadjustmentstobe madeat completionofthechecksandrepairs.
TROUBLESHOOTING
Troubleshootingchartscorrelating“Problems”to“Causes”arealsoincludedinthissection.
DISASSEMBLYANDASSEMBLY
Thissectionexplainstheordertobefollowedwhenremoving,installing,disassemblingorassemblingeach component,aswellasprecautionstobetakenfortheseoperations.
DIAGRAMSANDSCHEMATICS
Thissectionhasthefoldoutdrawingsforthemachine.
NOTICE
Thespecificationscontainedinthisshopmanualaresubjecttochangeatanytimeandwithoutanyadvancenotice.Contact yourdistributorforthelatestinformation.
12 HOWTOREADTHESHOPMANUAL
Thesevariousvolumesaredesignedtoavoidduplicationofinformation.Thereforetodealwithallrepairsfor anymodel,itisnecessarythatchassis,engine,electricalandattachmentbeavailable.
DISTRIBUTIONANDUPDATING
Anyadditions,amendmentsorotherchangeswillbe senttoyourdistributors.Getthemostup-to-dateinformationbeforeyoustartanywork.
SYMBOLS
Sothattheshopmanualcanbeofamplepracticaluse, importantplacesforsafetyandqualityaremarkedwith thefollowingsymbols.
SymbolItemRemarks
Safety
HCaution
Weight
Tightening torque
Specialsafetyprecautionsare necessarywhenperformingthe work.
Specialtechnicalprecautionsor otherprecautionsforpreservingstandardsarenecessary whenperformingthework.
Weightofpartsorsystems. Cautionnecessarywhen selectinghoistingwireorwhen workingpostureisimportant, etc.
Placesthatrequirespecial attentionfortighteningtorque duringassembly.
CoatPlacestobecoatedwithadhesivesandlubricantsetc.
Oil,water
Drain
Placeswhereoil,waterorfuel mustbeadded,andthecapacity.
Placeswhereoilorwatermust bedrained,andquantitytobe drained.
12
HOISTINGINSTRUCTIONS
HOISTING
WARNING!Heavyparts(25kgormore) mustbeliftedwithahoistetc. IntheDISASSEMBLYAND ASSEMBLYsection,every partweighing25kgormoreis indicatedclearlywiththesymbol.
Ifapartcannotbesmoothlyremovedfromthe machinebyhoisting,thefollowingchecksshould bemade:
1.Checkforremovalofallboltsfasteningthepartto therelativeparts.
2.Checkforexistenceofanotherpartcausinginterfacewiththeparttoberemoved.
WIREROPES
1.Useadequateropesdependingontheweightof partstobehoisted,referringtothetablebelow:
Wireropes
(Standard“Z”or“S”twistropeswithoutgalvanizing)
andaseriousaccidentcanresult.Hookshave maximumstrengthatthemiddleportion.
3.Donotslingaheavyloadwithoneropealone,but slingwithtwoormoreropessymmetricallywound ontotheload.
WARNING!Slingingwithoneropemay causeturningoftheload duringhoisting,untwistingof therope,orslippingofthe ropefromitsoriginalwinding positionontheload,which canresultinadangerous accident
4.Donotslingaheavyloadwithropesforminga widehanginganglefromthehook.Whenhoistinga loadwithtwoormoreropes,theforcesubjectedto eachropewillincreasewiththehangingangles. Thetablebelowshowsthevariationofallowable load(kg)whenhoistingismadewithtworopes, eachofwhichisallowedtoslingupto1000kgvertically,atvarioushangingangles.Whentworopes slingaloadvertically,upto2000kgoftotalweight canbesuspended.Thisweightbecomes1000kg whentworopesmakea120°hangingangle.On theotherhand,tworopesaresubjecttoanexcessiveforceaslargeas4000kgiftheyslinga2000 kgloadataliftingangleof150°.
Theallowableloadvalueisestimatedtobe1/6or 1/7ofthebreakingstrengthoftheropeused.
2.Slingwireropesfromthemiddleportionofthe hook.Slingingneartheedgeofthehookmay causetheropetoslipoffthehookduringhoisting,
