Komatsu 114E-3 Series Shop Manual SEN00169-21 PDF
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Komatsu 114E-3 Series Shop Manual SEN00169-21 – PDF DOWNLOAD
Description
Komatsu 114E-3 Series Shop Manual SEN00169-21 – PDF DOWNLOAD
FILE DETAILS:
Komatsu 114E-3 Series Shop Manual SEN00169-21 – PDF DOWNLOAD
Language : English
Pages : 492
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Komatsu 114E-3 Series Shop Manual SEN00169-21 – PDF DOWNLOAD
Cover . 1
00 Index and foreword . 3
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 53
Specification and technical data 53
General . 54
Specifications 55
General view 64
Dimensions table 88
Engine performance curves . 89
10 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 .145
Standard service value table 145
Standard value table for testing, adjusting and troubleshooting .146
Run-in standard and performance test criteria .153
30 Testing and adjusting 161
Testing and adjusting .161
Testing and adjusting tools list 163
Sketches of special tools .165
Testing air boost pressure 166
Adjusting valve clearance .167
Testing compression pressure 169
Testing blow-by pressure 172
Testing oil pressure 173
Handling fuel system parts 174
Releasing residual pressure in fuel system 174
Testing fuel pressure .175
Reduced cylinder mode operation .180
No-injection cranking .180
Testing leakage from pressure limiter and return rate from injector .181
Bleeding air from fuel circuit 183
Testing fuel system for leakage .184
Handling controller high-voltage circuit 185
Replacing alternator belt .185
40 Troubleshooting 187
General Information on troubleshooting 187
Points on troubleshooting .188
Error and failure code table 189
Information in troubleshooting table 192
Connection table for connector pin numbers 194
T- branch box and T- branch adapter table .230
Troubleshooting of electrical system (E-mode), Part 1 .235
Troubleshooting of electrical system (E-mode), Part 1 .237
E-1 Code [111/CA111] Engine Controller Internal Failure .237
E-2 Code [115/CA115] Eng. Ne and Bkup Speed Sensor Error 237
E-3 Code [122/CA122] Charge Air Press Sensor High Error .238
E-4 Code [123/CA123] Charge Air Press Sensor Low Error 240
E-5 Code [131/CA131] Throttle Sensor High Error .242
E-6 Code [132/CA132] Throttle Sensor Low Error 244
E-7 Code [144/CA144] Coolant Temp. Sensor High Error 246
E-8 Code [145/CA145] Coolant Temp. Sensor Low Error .248
E-9 Code [153/CA153] Charge Air Temp. Sensor High Error .250
E-10 Code [154/CA154] Charge Air Temp. Sensor Low Error .252
E-11 Code [155/CA155] Charge Air Press. High Speed Derate .254
E-12 Code [187/CA187] Sensor Sup. 2 Volt. Low Error .256
E-13 Code [221/CA221] Ambient Air Press. Sensor High Error 258
E-14 Code [222/CA222] Ambient Air Press. Sensor Low Error .260
E-15 Code [227/CA227] Abnormally high level in sensor power supply 2 circuit 262
E-16 Code [234/CA234] Eng. Overspeed 263
E-17 Code [238/CA238] Ne Speed Sensor Sup. Volt. Error 264
E-18 Code [271/CA271] IMV (IMA) Short Error .265
E-19 Code [272/CA272] IMV (IMA) Open Error 266
E-20 Code [281/CA281] High pressure pump error 268
E-21 Code [322/CA322] Injector No. 1 System Open/Short Error 270
E-22 Code [323/CA323] Injector No. 5 System Open/Short Error 272
E-23 Code [324/CA324] Injector No. 3 System Open/Short Error 274
E-24 Code [325/CA325] Injector No. 6 System Open/Short Error 276
E-25 Code [331/CA331] Injector No. 2 System Open/Short Error 278
E-26 Code [332/CA332] Injector No. 4 System Open/Short Error 280
E-27 Code [342/CA342] Engine Controller Data Matching Error .282
Troubleshooting of electrical system (E-mode), Part 2 .285
Troubleshooting of electrical system (E-mode), Part 2 .287
E-28 Code [351/CA351] INJ. Drive Circuit Error 287
E-29 Code [352/CA352] Sensor Sup. 1 Volt. Low Error .289
E-30 Code [386/CA386] Sensor Sup. 1 Volt. High Error 291
E-31 Code [428/CA428] Water Sensor High Level Error .292
E-32 Code [429/CA429] Water Sensor Low Level Error 294
E-33 Code [431/CA431] Idle Validation Switch Error 296
E-34 Code [432/CA432] Idle Validation Process Error .298
E-35 Code [435/CA435] Eng. Oil Switch Error .300
E-36 Code [441/CA441] Supply Voltage Low Error 302
E-37 Code [442/CA442] Supply Voltage High Error .304
E-38 Code [449/CA449] Rail Press. High Error 2 306
E-39 Code [451/CA451] Rail Press. Sensor High Error .308
E-40 Code [452/CA452] Rail Press. Sensor Low Error 310
E-41 Code [488/CA488] Charge Air Temp. High Torque Derate .312
E-42 Code [553/CA553] Rail Press. High Error 1 313
E-43 Code [559/CA559] Rail Press Low Error 314
E-44 Code [689/CA689] Eng. Ne Speed Sensor Error 316
E-45 Code [731/CA731] Eng. Bkup Speed Sensor Phase Error 318
E-46 Code [757/CA757] All Engine Controller Data Lost Error .320
E-47 Code [778/CA778] Eng. Bkup Speed Sensor Error 322
E-48 Code [1633/CA1633] KOMNET Error 324
E-49 Code [2185/CA2185] Throttle Sens. Sup. Volt. High Error 326
E-50 Code [2186/CA2186] Throttle Sens. Sup. Volt. Low Error .327
E-51 Code [2249/CA2249] Rail Press very Low Error .328
E-52 Code [2265/CA2265] Abnormally high level in electric lift pump .330
E-53 Code [2266/CA2266] Abnormally low level in electric lift pump 332
E-54 Code [2311/CA2311] IMV (IMA) Solenoid Error 334
E-55 Code [2555/CA2555] Intake Air Heater Relay Supply Voltage Low Error 336
E-56 Code [2556/CA2556] Intake Air Heater Relay Supply Voltage High Error .338
E-57 Code [—/B@BAZG] Eng. Oil Press. Low Speed Derate .340
E-58 Code [—/B@BAZG] Eng. Oil Press Low Torque Derate .340
E-59 Code [—/B@BCNS] Eng. Overheat 341
Troubleshooting of mechanical system (S-mode) .343
Troubleshooting of mechanical system (S-mode) .345
Method of using troubleshooting charts 345
S-1 Starting performance is poor 348
S-2 Engine does not start .349
S-3 Engine does not pick up smoothly 352
S-4 Engine stops during operations 353
S-5 Engine does not rotate smoothly .354
S-6 Engine lacks output (or lacks power) 355
S-7 Exhaust smoke is black (incomplete combustion) 356
S-8 Oil consumption is excessive (or exhaust smoke is blue) .357
S-9 Oil becomes contaminated quickly 358
S-10 Fuel consumption is excessive 359
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) 360
S-12 Oil pressure drops .361
S-13 Oil level rises (Entry of coolant or fuel) .362
S-14 Coolant temperature becomes too high (overheating) .363
S-15 Abnormal noise is made .364
S-16 Vibration is excessive .365
50 Disassembly and assembly .367
General information on disassembly and assembly .367
How to read this manual .368
Coating materials list 370
Special tool list .374
Disassembly and assembly, Part 1 377
Disassembly and assembly 378
General disassembly of engine .378
Disassembly and assembly, Part 2 395
General assembly of engine 396
Disassembly and assembly, Part 3 429
Disassembly and assembly 430
Disassembly and assembly of supply pump .430
90 Repair and Replacement of parts 441
Information related repair and replacement 441
Special tool table 442
Parts related to cylinder head 445
Dimensions of cylinder heads 446
Checking of valves 447
Pressure test .451
Vacuum test of valve seat insert 453
Cleaning and checking of cylinder head bolts 454
Parts related to cylinder block .457
Replacement of camshaft bushings 458
Cleaning and checking of cylinder liners before reuse .460
Cleaning and checking of pistons before reuse .472
Cleaning and checking of crankshafts before reuse .474
Replacement of crankshaft gears .476
Cleaning and checking of main bearings before reuse .479
Cleaning and checking of main bearing metal caps and mounting bolts before reuse 480
Cleaning and checking of connecting rods before reuse .482
Checking of connecting rods for bending and twisting 484
Replacement of connecting rod bushings 487
DESCRIPTION:
Komatsu 114E-3 Series Shop Manual SEN00169-21 – PDF DOWNLOAD
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.
2. Revision and distribution
Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most
up-to-date information before you start any work
G.B 25/12/24
