Komatsu 114E-3 Series Engine Shop Manual SEN00169-19 – PDF DOWNLOAD

Komatsu 114E-3 Series Engine Shop Manual SEN00169-19 – PDF DOWNLOAD

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Komatsu 114E-3 Series Engine Shop Manual SEN00169-19 – PDF DOWNLOAD

Language : English
Pages : 490
Downloadable : Yes
File Type : PDF
Size: 36.2 MB

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Komatsu 114E-3 Series Engine Shop Manual SEN00169-19 – PDF DOWNLOAD

1. Composition of shop manual
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)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
This section explains the method of reproducing, repairing, and replacing parts.

TABLE OF CONTENTS:

Komatsu 114E-3 Series Engine Shop Manual SEN00169-19 – PDF DOWNLOAD

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
Specifications……………………………………………………………. 55
General view……………………………………………………………… 64
Dimensions table………………………………………………………….. 88
Engine performance curves………………………………………………….. 89
10 Structure, function and maintenance standard……………………………………… 0
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