KOMATSU 114E-3 SERIES Service Repair Manual (SEN00169-15) – PDF DOWNLOAD

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KOMATSU 114E-3 SERIES Service Repair Manual (SEN00169-15)

KOMATSU 114E-3 SERIES SERVICE REPAIR MANUAL (SEN00169-15) – PDF DOWNLOAD:

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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]