KOMATSU 114E-3 SERIES Service Repair Manual (SEN00169-15)
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KOMATSU 114E-3 SERIES Service Repair Manual (SEN00169-15)
- This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections.
- 00. Index and foreword
This section explains the shop manuals list, table of contents, safety, and basic information. - 01. Specification
This section explains the specifications of the machine. - 10. Structure, function and maintenance standard
This section explains the structure, function, and maintenance standard values of each component. The structure and function sub-section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. The maintenance standard sub-section explains the criteria and remedies for disassembly and service. - 20. Standard value table
This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting. - 30. Testing and adjusting
This section explains measuring instruments and measuring methods for testing and adjusting, and method of adjusting each part. The standard values and judgement criteria for testing and adjusting are explained in Testing and adjusting. - 40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also explained in the Chassis volume and Engine volume. In this case, see the Chassis volume. - 50. Disassembly and assembly
This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque and quantity and weight of coating material, oil, grease, and coolant necessary for the work are also explained. - 90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
Engine volume
This section explains the method of reproducing, repairing, and replacing parts
TABLE OF CONTENTS:
KOMATSU 114E-3 SERIES Service Repair Manual (SEN00169-15)
COVER ...................................................................................... 1 00 Index and foreword....................................................................... 0 Index................................................................................... 3 Composition of shop manual.......................................................... 4 Table of contents................................................................... 5 Foreword and general information........................................................ 11 Safety notice....................................................................... 12 How to read the shop manual......................................................... 17 Explanation of terms for maintenance standard....................................... 19 Handling of electric equipment and hydraulic component.............................. 21 Handling of connectors newly used for engines....................................... 30 How to read electric wire code...................................................... 33 Precautions when carrying out operation............................................. 36 Method of disassembling and connecting push-pull type coupler....................... 39 Standard tightening torque table.................................................... 42 Conversion table.................................................................... 46 01 Specification............................................................................ 0 Specification and technical data........................................................ 53 General............................................................................. 54 pecifications....................................................................... 55 General view........................................................................ 64 Dimensions table.................................................................... 88 Engine performance curves........................................................... 89 10 Structure, function and maintenance standard............................................. 0 Structure, function and maintenance standard............................................ 97 Intake, exhaust system ............................................................. 99 Intake system................................................................... 99 Exhaust system .................................................................100 Turbocharger....................................................................101 Lubricating oil system..............................................................104 Cooling system......................................................................106 Fuel system (common rail) ..........................................................108 Maintenance standard................................................................113 Turbocharger....................................................................113 Cylinder head...................................................................114 Cylinder block..................................................................116 Cylinder liner..................................................................118 Crankshaft......................................................................120 Piston, piston ring and piston pin..............................................121 Connecting rod..................................................................122 Vibration damper................................................................124 Timing gear.....................................................................125 Camshaft........................................................................126 Valve and valve guide...........................................................128 Rocker arm, shaft and tappet....................................................130 Flywheel and flywheel housing...................................................132 Oil pump........................................................................134 Water pump drive................................................................136 Water pump......................................................................137 Thermostat......................................................................138 Fan drive.......................................................................139 Alternator......................................................................140 Starting motor..................................................................142 20 Standard value table..................................................................... 0 Standard service value table............................................................145 Standard value table for testing, adjusting and troubleshooting.....................146 Run-in standard and performance test criteria.......................................152 30 Testing and adjusting.................................................................... 0 Testing and adjusting...................................................................159 Testing and adjusting tools list....................................................161 Sketches of special tools...........................................................163 Testing air boost pressure..........................................................164 Adjusting valve clearance...........................................................165 Testing compression pressure........................................................167 Testing blow-by pressure............................................................170 Testing oil pressure................................................................171 Handling fuel system parts..........................................................172 Releasing residual pressure in fuel system..........................................172 Testing fuel pressure...............................................................173 Reduced cylinder mode operation.....................................................178 No-injection cranking...............................................................178 Testing leakage from pressure limiter and return rate from injector.................179 Bleeding air from fuel circuit......................................................181 Testing fuel system for leakage.....................................................182 Handling controller high-voltage circuit............................................183 Replacing alternator belt...........................................................183 40 Troubleshooting.......................................................................... 0 General Information on troubleshooting..................................................185 Points on troubleshooting...........................................................186 Error and failure code table........................................................187 Information in troubleshooting table................................................190 Connection table for connector pin numbers..........................................192 T- branch box and T- branch adapter table...........................................228 Troubleshooting of electrical system (E-mode), Part 1...................................233 Troubleshooting of electrical system (E-mode), Part 1...............................235 E-1 Code [111/CA111] Engine Controller Internal Failure.........................235 E-2 Code [115/CA115] Eng. Ne and Bkup Speed Sensor Error........................235 E-3 Code [122/CA122] Charge Air Press Sensor High Error.........................236 E-4 Code [123/CA123] Charge Air Press Sensor Low Error..........................238 E-5 Code [131/CA131] Throttle Sensor High Error.................................240 E-6 Code [132/CA132] Throttle Sensor Low Error..................................242 E-7 Code [144/CA144] Coolant Temp. Sensor High Error............................244 E-8 Code [145/CA145] Coolant Temp. Sensor Low Error.............................246 E-9 Code [153/CA153] Charge Air Temp. Sensor High Error.........................248 E-10 Code [154/CA154] Charge Air Temp. Sensor Low Error.........................250 E-11 Code [155/CA155] Charge Air Press. High Speed Derate.......................252 E-12 Code [187/CA187] Sensor Sup. 2 Volt. Low Error.............................254 E-13 Code [221/CA221] Ambient Air Press. Sensor High Error......................256 E-14 Code [222/CA222] Ambient Air Press. Sensor Low Error.......................258 E-15 Code [227/CA227] Abnormally high level in sensor power supply 2 circuit....260 E-16 Code [234/CA234] Eng. Overspeed............................................261 E-17 Code [238/CA238] Ne Speed Sensor Sup. Volt. Error..........................262 E-18 Code [271/CA271] IMV (IMA) Short Error.....................................263 E-19 Code [272/CA272] IMV (IMA) Open Error......................................264 E-20 Code [281/CA281] High pressure pump error..................................266 E-21 Code [322/CA322] Injector No. 1 System Open/Short Error....................268 E-22 Code [323/CA323] Injector No. 5 System Open/Short Error....................270 E-23 Code [324/CA324] Injector No. 3 System Open/Short Error....................272 E-24 Code [325/CA325] Injector No. 6 System Open/Short Error....................274 E-25 Code [331/CA331] Injector No. 2 System Open/Short Error....................276 E-26 Code [332/CA332] Injector No. 4 System Open/Short Error....................278 E-27 Code [342/CA342] Engine Controller Data Matching Error.....................280 Troubleshooting of electrical system (E-mode), Part 2...................................283 Troubleshooting of electrical system (E-mode), Part 2...............................285 E-28 Code [351/CA351] INJ. Drive Circuit Error..................................285 E-29 Code [352/CA352] Sensor Sup. 1 Volt. Low Error.............................287 E-30 Code [386/CA386] Sensor Sup. 1 Volt. High Error............................289 E-31 Code [428/CA428] Water Sensor High Level Error.............................290 E-32 Code [429/CA429] Water Sensor Low Level Error..............................292 E-33 Code [431/CA431] Idle Validation Switch Error..............................294 E-34 Code [432/CA432] Idle Validation Process Error.............................296 E-35 Code [435/CA435] Eng. Oil Switch Error.....................................298 E-36 Code [441/CA441] Supply Voltage Low Error..................................300 E-37 Code [442/CA442] Supply Voltage High Error.................................302 E-38 Code [449/CA449] Rail Press. High Error 2..................................304 E-39 Code [451/CA451] Rail Press. Sensor High Error.............................306 E-40 Code [452/CA452] Rail Press. Sensor Low Error..............................308 E-41 Code [488/CA488] Charge Air Temp. High Torque Derate.......................310 E-42 Code [553/CA553] Rail Press. High Error 1..................................311 E-43 Code [559/CA559] Rail Press Low Error......................................312 E-44 Code [689/CA689] Eng. Ne Speed Sensor Error................................314 E-45 Code [731/CA731] Eng. Bkup Speed Sensor Phase Error........................316 E-46 Code [757/CA757] All Engine Controller Data Lost Error.....................318 E-47 Code [778/CA778] Eng. Bkup Speed Sensor Error..............................320 E-48 Code [1633/CA1633] KOMNET Error............................................322 E-49 Code [2185/CA2185] Throttle Sens. Sup. Volt. High Error....................324 E-50 Code [2186/CA2186] Throttle Sens. Sup. Volt. Low Error.....................325 E-51 Code [2249/CA2249] Rail Press very Low Error...............................326 E-52 Code [2265/CA2265] Abnormally high level in electric lift pump.............328 E-53 Code [2266/CA2266] Abnormally low level in electric lift pump..............330 E-54 Code [2311/CA2311] IMV (IMA) Solenoid Error................................332 E-55 Code [2555/CA2555] Intake Air Heater Relay Supply Voltage Low Error........334 E-56 Code [2556/CA2556] Intake Air Heater Relay Supply Voltage High Error.......336 E-57 Code [---/B@BAZG] Eng. Oil Press. Low Speed Derate.........................338 E-58 Code [---/B@BAZG] Eng. Oil Press Low Torque Derate.........................338 E-59 Code [---/B@BCNS] Eng. Overheat............................................339 Troubleshooting of mechanical system (S-mode)...........................................341 Troubleshooting of mechanical system (S-mode).......................................343 Method of using troubleshooting charts..........................................343 S-1 Starting performance is poor................................................346 S-2 Engine does not start.......................................................347 S-3 Engine does not pick up smoothly............................................350 S-4 Engine stops during operations..............................................351 S-5 Engine does not rotate smoothly.............................................352 S-6 Engine lacks output (or lacks power)........................................353 S-7 Exhaust smoke is black (incomplete combustion)..............................354 S-8 Oil consumption is excessive (or exhaust smoke is blue).....................355 S-9 Oil becomes contaminated quickly............................................356 S-10 Fuel consumption is excessive..............................................357 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)......358 S-12 Oil pressure drops.........................................................359 S-13 Oil level rises (Entry of coolant or fuel).................................360 S-14 Coolant temperature becomes too high (overheating).........................361 S-15 Abnormal noise is made.....................................................362 S-16 Vibration is excessive.....................................................363 50 Disassembly and assembly................................................................. 0 General information on disassembly and assembly.........................................365 How to read this manual.............................................................366 Coating materials list..............................................................368 Special tool list...................................................................372 Disassembly and assembly, Part 1........................................................375 Disassembly and assembly............................................................376 General disassembly of engine...................................................376 Disassembly and assembly, Part 2........................................................393 Disassembly and assembly............................................................394 General assembly of engine......................................................394 Disassembly and assembly, Part 3........................................................427 Disassembly and assembly............................................................428 Disassembly and assembly of supply pump.........................................428 90 Repair and Replacement of parts.......................................................... 0 Information related repair and replacement..............................................439 Special tool table..................................................................440 Parts related to cylinder head..........................................................443 Dimensions of cylinder heads........................................................444 Checking of valves..................................................................445 Pressure test.......................................................................449 Vacuum test of valve seat insert....................................................451 Cleaning and checking of cylinder head bolts........................................452 Parts related to cylinder block.........................................................455 Replacement of camshaft bushings....................................................456 Cleaning and checking of cylinder liners before reuse...............................458 Cleaning and checking of pistons before reuse.......................................470 Cleaning and checking of crankshafts before reuse...................................472 Replacement of crankshaft gears.....................................................474 Cleaning and checking of main bearings before reuse.................................477 Cleaning and checking of main bearing metal caps and mounting bolts before reuse....478 Cleaning and checking of connecting rod bearings before reuse.......................478 Cleaning and checking of connecting rods before reuse...............................480 Checking of connecting rods for bending and twisting................................482 Replacement of connecting rod bushings..............................................485
PLEASE NOTE:
⦁ This is the SAME exact manual used by your dealers to fix your vehicle.
⦁ The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
⦁ Any queries / doubts regarding your purchase, please feel free to contact [email protected]