Komatsu 114, 114E Series Engines Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu 114, 114E Series Engines, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu 114, 114E Series Engines workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 5,285 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
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SEBM024603 - 114 Series Diesel Engines (SAA6D114E-2) Shop Manual.pdf
SEN00169-15 - 114E-3 Series Engines Shop Manual.pdf
SEN00169-13 - 114E-3 Series Engines (SAA6D114E-3) Shop Manual.pdf
SEN00169-09 - 114E-3 Series Engines (SAA6D114E-3) Shop Manual.pdf
SEN05537-01 - 114E-5 Series Engines Shop Manual.pdf
SEN00169-05 - 114E-3 Series Engines (SAA6D114E-3) Shop Manual.pdf
SEN00169-00 - 114E-3 Series Engines (SAA6D114E-3) Shop Manual.pdf
MAIN SECTIONS
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...91
Specification and technical data...92
General...92
Specifications...93
General view...100
Dimensions table...120
Engine performance curves...121
10 Structure, function and maintenance standard...0
Structure, function and maintenance standard...0
Intake, exhaust system...0
Intake system...0
Exhaust system...0
Turbocharger...0
Lubricating oil system...0
Cooling system...0
Fuel system (common rail)...0
Maintenance standard...0
Turbocharger...0
Cylinder head...0
Cylinder block...0
Cylinder liner...0
Crankshaft...0
Piston, piston ring and piston pin...0
Connecting rod...0
Vibration damper...0
Timing gear...0
Camshaft...0
Valve and valve guide...0
Rocker arm, shaft and tappet...0
Flywheel and flywheel housing...0
Oil pump...0
20 Standard value table...0
Standard service value table...129
Standard service value table...130
Standard value table for testing, adjusting and troubleshooting...130
Run-in standard and performance test criteria...135
30 Testing and adjusting...0
Testing and adjusting...141
Testing and adjusting tools list...143
Sketches of special tools...145
Testing air boost pressure...146
Adjusting valve clearance...147
Testing compression pressure...149
Testing blow-by pressure...152
Testing oil pressure...153
Handling fuel system parts...154
Releasing residual pressure in fuel system...154
Testing fuel pressure...155
Reduced cylinder mode operation...160
No-injection cranking...160
Testing leakage from pressure limiter and return rate from injector...161
Bleeding air from fuel circuit...163
Testing fuel system for leakage...164
Handling controller high-voltage circuit...165
Replacing alternator belt...165
40 Troubleshooting...0
General Information on troubleshooting...167
Points on troubleshooting...168
Error and failure code table...169
Information in troubleshooting table...172
Connection table for connector pin numbers...174
T- branch box and T- branch adapter table...210
Troubleshooting of electrical system (E-mode), Part 1...215
Troubleshooting of electrical system (E-mode), Part 1...217
E-1 Code [111/CA111] Engine Controller Internal Failure...217
E-2 Code [115/CA115] Eng. Ne and Bkup Speed Sensor Error...217
E-3 Code [122/CA122] Charge Air Press Sensor High Error...218
E-4 Code [123/CA123] Charge Air Press Sensor Low Error...220
E-5 Code [131/CA131] Throttle Sensor High Error...222
E-6 Code [132/CA132] Throttle Sensor Low Error...224
E-7 Code [144/CA144] Coolant Temp. Sensor High Error...226
E-8 Code [145/CA145] Coolant Temp. Sensor Low Error...228
E-9 Code [153/CA153] Charge Air Temp. Sensor High Error...230
E-10 Code [154/CA154] Charge Air Temp. Sensor Low Error...232
E-11 Code [155/CA155] Charge Air Press. High Speed Derate...234
E-12 Code [187/CA187] Sensor Sup. 2 Volt. Low Error...236
E-13 Code [221/CA221] Ambient Air Press. Sensor High Error...238
E-14 Code [222/CA222] Ambient Air Press. Sensor Low Error...240
E-15 Code [227/CA227] Abnormally high level in sensor power supply 2 circuit...242
E-16 Code [234/CA234] Eng. Overspeed...243
E-17 Code [238/CA238] Ne Speed Sensor Sup. Volt. Error...244
E-18 Code [271/CA271] IMV (IMA) Short Error...245
E-19 Code [272/CA272] IMV (IMA) Open Error...246
E-20 Code [281/CA281] High pressure pump error...248
E-21 Code [322/CA322] Injector No. 1 System Open/Short Error...250
E-22 Code [323/CA323] Injector No. 5 System Open/Short Error...252
E-23 Code [324/CA324] Injector No. 3 System Open/Short Error...254
E-24 Code [325/CA325] Injector No. 6 System Open/Short Error...256
E-25 Code [331/CA331] Injector No. 2 System Open/Short Error...258
E-26 Code [332/CA332] Injector No. 4 System Open/Short Error...260
E-27 Code [342/CA342] Engine Controller Data Matching Error...262
Troubleshooting of electrical system (E-mode), Part 2...265
Troubleshooting of electrical system (E-mode), Part 2...267
E-28 Code [351/CA351] INJ. Drive Circuit Error...267
E-29 Code [352/CA352] Sensor Sup. 1 Volt. Low Error...269
E-30 Code [386/CA386] Sensor Sup. 1 Volt. High Error...271
E-31 Code [428/CA428] Water Sensor High Level Error...272
E-32 Code [429/CA429] Water Sensor Low Level Error...274
E-33 Code [431/CA431] Idle Validation Switch Error...276
E-34 Code [432/CA432] Idle Validation Process Error...278
E-35 Code [435/CA435] Eng. Oil Switch Error...280
E-36 Code [441/CA441] Supply Voltage Low Error...282
E-37 Code [442/CA442] Supply Voltage High Error...284
E-38 Code [449/CA449] Rail Press. High Error 2...286
E-39 Code [451/CA451] Rail Press. Sensor High Error...288
E-40 Code [452/CA452] Rail Press. Sensor Low Error...290
E-41 Code [488/CA488] Charge Air Temp. High Torque Derate...292
E-42 Code [553/CA553] Rail Press. High Error 1...293
E-43 Code [559/CA559] Rail Press Low Error...294
E-44 Code [689/CA689] Eng. Ne Speed Sensor Error...296
E-45 Code [731/CA731] Eng. Bkup Speed Sensor Phase Error...298
E-46 Code [757/CA757] All Engine Controller Data Lost Error...300
E-47 Code [778/CA778] Eng. Bkup Speed Sensor Error...302
E-48 Code [1633/CA1633] KOMNET Error...304
E-49 Code [2185/CA2185] Throttle Sens. Sup. Volt. High Error...306
E-50 Code [2186/CA2186] Throttle Sens. Sup. Volt. Low Error...307
E-51 Code [2249/CA2249] Rail Press very Low Error...308
E-52 Code [2265/CA2265] Abnormally high level in electric lift pump...310
E-53 Code [2266/CA2266] Abnormally low level in electric lift pump...312
E-54 Code [2311/CA2311] IMV (IMA) Solenoid Error...314
E-55 Code [2555/CA2555] Intake Air Heater Relay Supply Voltage Low Error...316
E-56 Code [2556/CA2556] Intake Air Heater Relay Supply Voltage High Error...318
E-57 Code [---/B@BAZG] Eng. Oil Press. Low Speed Derate...320
E-58 Code [---/B@BAZG] Eng. Oil Press Low Torque Derate...320
E-59 Code [---/B@BCNS] Eng. Overheat...321
Troubleshooting of mechanical system (S-mode)...323
Troubleshooting of mechanical system (S-mode)...325
Method of using troubleshooting charts...325
S-1 Starting performance is poor...328
S-2 Engine does not start...329
S-3 Engine does not pick up smoothly...332
S-4 Engine stops during operations...333
S-5 Engine does not rotate smoothly...334
S-6 Engine lacks output (or lacks power)...335
S-7 Exhaust smoke is black (incomplete combustion)...336
S-8 Oil consumption is excessive (or exhaust smoke is blue)...337
S-9 Oil becomes contaminated quickly...338
S-10 Fuel consumption is excessive...339
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)...340
S-12 Oil pressure drops...341
S-13 Oil level rises (Entry of coolant or fuel)...342
S-14 Coolant temperature becomes too high (overheating)...343
S-15 Abnormal noise is made...344
S-16 Vibration is excessive...345
50 Disassembly and assembly...0
General information on disassembly and assembly...347
How to read this manual...348
Coating materials list...350
Special tool list...354
Disassembly and assembly, Part 1...357
Disassembly and assembly...358
General disassembly of engine...358
Disassembly and assembly, Part 2...375
Disassembly and assembly...376
General assembly of engine...376
Disassembly and assembly, Part 3...409
Disassembly and assembly...410
Disassembly and assembly of supply pump...410
90 Repair and Replacement of parts...0
Information related repair and replacement...421
Special tool table...422
Parts related to cylinder head...425
Dimensions of cylinder heads...426
Checking of valves...427
Pressure test...431
Vacuum test of valve seat insert...433
Cleaning and checking of cylinder head bolts...434
Parts related to cylinder block...437
Replacement of camshaft bushings...438
Cleaning and checking of cylinder liners before reuse...440
Cleaning and checking of pistons before reuse...452
Cleaning and checking of crankshafts before reuse...454
Replacement of crankshaft gears...456
Cleaning and checking of main bearings before reuse...459
Cleaning and checking of main bearing metal caps and mounting bolts before reuse...460
Cleaning and checking of connecting rod bearings before reuse...460
Cleaning and checking of connecting rods before reuse...462
Checking of connecting rods for bending and twisting...464
Replacement of connecting rod bushings...467
